Why 10 Colors Is Not “Better 6″—It’s a Different Technology

The first misconception I hear from brand managers: “10 colors is simply more colors.” Not quite. 10 colors simply provides a different set of tools.

Classic four-color printing (CMYK) is the baseline. Cyan, magenta, yellow, black—theoretically, you can compose any color from these four inks. In practice: you cannot. Beyond the reach of CMYK are Pantones, opaque white, varnish, as well as metallics and fluorescents.

Each of these tools is a separate printing station. 6 colors typically means CMYK + two spot colors (most often opaque white + one brand Pantone). 8 colors means CMYK + four additional tools. 10 colors means CMYK + six tools—i.e., a full brand book in one pass of the film through the machine.

What does this give you in practice? You can have exactly that brand shade you have on carton packaging and in digital communication. You can add opaque white under the color so it looks intense even on transparent film. You can add spot varnish to the logo so there is a depth effect on the shelf. You can add a fluorescent that the competition does not have—and the customer’s eye searches for it from a meter and a half away.

The second technological layer: the type of press. Flexo CI (central impression)—with one large central cylindrical drum around which printing stations are arranged—is the premium standard for wide-web. The film is held on the central drum and passes through successive stations without relative movement. Result: perfect color registration (±0.1 mm), zero misalignment on thin films, ability to operate at speeds of 400 m/min.

Other architectures (in-line, stack) are cheaper, but provide poorer color registration on thin PE films. This does not mean they are bad—they simply have different applications. For pellet bags or pallet hoods—they suffice. For beverage multipacks or a pack of toilet paper on the shelf at Lidl—they do not.

And the third dimension: inks. Water-based vs. solvent-based. Water-based inks are now the standard in the packaging industry, as they produce approximately 4 kg CO2e/m² carbon footprint—compared to 12–15 kg for solvent-based inks. Plus no VOCs, no odor, no food contact restrictions. But they require more expensive equipment and a more controlled drying process.

10 colors on flexo CI with water-based inks is not simply “more colors,” but a different technological standard.

Two Printing Systems—In-Line vs. Standalone

At Kablonex, we have both. This is deliberate, because different applications require different solutions.

In-line printing is printing directly from the extrusion line. The film comes out of the extruder, is printed in the same line, and wound onto a roll ready for shipment. Advantage: shorter production cycle, lower unit cost, one process instead of two. Disadvantage: narrower parameter window. In-line printing in our portfolio goes up to 6 colors. This is sufficient for pallet branding and industrial bags, where the number of colors is not the most important factor, but unit cost is.

Example: NEX-HOOD NHD (printed stretch-hood) up to 6 colors, 1800 mm width, with the option to combine printing with PCR dosing. Ideal for pellet pallets with manufacturer logo, fertilizer pallets with distributor branding, construction chemical pallets with GHS pictograms.

Standalone printing is printing on a separate printing line, independent of extrusion. At Kablonex, we have 4 such machines—up to 10 colors, web widths of 300–1800 mm, speeds of 400 m/min. Advantage: full control of print quality, process separation, ability to work with films from various sources (including laminates). Disadvantage: two processes instead of one, higher unit cost.

This is the system for premium retail applications: FMCG packaging on retail chain shelves, beverage multipacks, toilet paper in premium lines, frozen foods in the premium segment, hygiene materials under retail chain private labels.

The decision rule is simple. Are you packaging a logistics product that does not compete visually? In-line, up to 6 colors. Are you packaging an FMCG product that sits on the shelf next to competitors and has 0.3 seconds to catch the customer’s eye? Standalone, up to 10 colors.

Most myths about flexo printing stem from someone trying to apply in-line where standalone was needed, or vice versa. Result: printing that does not meet brand book expectations, or unnecessarily high production cost.

When 6 Colors Are Enough (and It Makes No Sense to Pay for 10)

Here is my clear opinion: in most industrial applications, 10 colors is overkill.

FFS bags with construction chemicals, cement, wood pellets—you print in 4 colors. Logo, product name, EAN and GHS codes, one spot color for the brand. The end customer does not buy cement visually, they buy it by technical specification and price. Investing in 10 colors on a cement bag is wasted money.

Pallet stretch-hood—you print in a maximum of 6 colors, because the pallet is not a product on the shelf. It is a logo carrier in the logistics chain. What matters here is different: print durability, opaque white under intense color, and UV resistance. Six colors on good film will give a better result than ten on poor film.

Example from our portfolio. A domestic fertilizer manufacturer with exports to Europe. They packaged pallets in stretch-hood with flexo printing. The logo contained intense red—a color that fades fastest under UV in classic flexo printing. After several weeks to several months of outdoor storage at distributors, the logo faded, the pallet ceased to function as a brand carrier, sales networks reported lack of visual consistency.

Solution: NEX-HOOD NHD 70 µm in opaque white version, in-line printing in 6 colors with inks of enhanced UV resistance (with emphasis on red stability), UV stabilizer in the film itself, and UV absorber protecting the product inside the pallet. Plus downgauging from 90 µm to 70 µm—because the 5-layer construction with mLLDPE allowed thickness reduction without loss of stabilization parameters.

Results: elimination of complaints for print fading, pallet maintains brand visual consistency throughout the logistics cycle, 22% less film per pallet, protection of fertilizer product from UV degradation. Implementation without modification of the packaging line.

Key takeaway: this case did not require 10 colors. It required better technology within 6 colors. Opaque white + UV stabilizer + good film. This is the quiet revolution in industrial packaging—most problems are solved by ink chemistry and film construction, not by the number of colors.

10 colors make sense when the product genuinely competes visually. Cement bags—do not compete. Fertilizer pallets—do not compete. Pallet stretch-hood—does not compete. Investing in 10 colors in these applications is a classic example of spending money where it does not return.

When 10 Colors Pay Off in Sales

Three situations in which 10 colors are not extravagance, but a return-on-investment.

Situation 1: FMCG Retail Shelf. Your product sits on the shelf at Biedronka, Lidl, Carrefour, or Auchan. The customer walks by with a basket, has 0.3 seconds to catch their eye. The competition prints in 8–10 colors with opaque white and spot varnish, your packaging is in 4 colors on transparent film. Result: the customer sees the competition, does not see you. This is not theory, but real sales data from shelf studies—products with premium packaging have higher turnover, even at similar prices.

Situation 2: Brand with Extended Color Palette. Your brand book has 6 Pantone colors, two spot colors, and varnish. Attempting to reproduce this in CMYK will result in your orange being different on the packaging than on the website, in commercials, and in POS materials. This is not a detail—it is the foundation of brand visual consistency. 10-color flexo CI allows you to reproduce the full brand book in one pass of the film through the machine, without compromises.

Situation 3: Export to Chains with Rigorous Brand Compliance. German chains (REWE, Edeka, Aldi), British chains (Tesco, Sainsbury’s), and Scandinavian chains (ICA, Coop) increasingly require suppliers to fully comply with the customer’s brand book. This means: exact Pantone, opaque white under color, spot varnish, controlled print shrinkage after shrinking. If you print in 4 colors, the chain rejects you or gives conditional entry. With 10 colors, you are the standard.

These are three situations. If at least one applies to your product—10 colors is an investment, not a cost.

Case Study—Premium Toilet Paper with 55% PCR and 10 Colors

One of the most interesting projects in recent years in our portfolio.

Client: hygiene products manufacturer from Central Europe, toilet paper and towels. Two product lines—standard and premium. Business objectives: reduction of plastic footprint (ESG, reporting under PPWR), maintaining machinability on packaging lines, raising the visual standard of the premium line, introducing high PCR content.

Technical challenge: three parameters that classically exclude each other. Thinner film (material savings), more PCR (ESG goal), better printing (premium look). Thinner film usually means loss of mechanical parameters. More PCR means loss of transparency and print quality. More colors means more printing processes and risk of registration misalignment.

Solution: paradigm shift in film construction. A new, multilayer formulation with enhanced mechanical parameters allowed downgauging from 35–40 µm to 28 µm, with simultaneous implementation of 35% PCR in the standard line and up to 55% PCR in the premium variant. Standalone printing on flexo CI, 10 colors with water-based inks, integration with two of the client’s product lines. Machine validation on the client’s line before first delivery.

Results:

• significant reduction in plastic consumption per packaging unit
• achievement of ESG goals and PPWR requirements with strong buffer
• maintained machinability and logistics safety
• premium 10-color printing on both product lines
• stronger client position in negotiations with retail chains

Key takeaway from this case: 10 colors was not the client’s marketing wishlist, but a requirement of the premium line brand book and the chains to which the product is distributed. Without 10 colors, this project would not have closed, regardless of how good the film was.

This is, in my opinion, the most frequently overlooked aspect of the decision on the number of colors: the number of colors is not a marketing decision, but a business decision. It depends on where you sell, to whom, and with what ambition.

What Besides the Number of Colors Determines Print Quality

Brand managers ask me: “We print in 8 colors, why is the result worse than the competition’s in 6?” Answer: because the number of colors is one of the parameters. There are four more that decide.

Anilox Roller and Line Screen. Anilox is a ceramic roller that transfers ink to the printing plate. The higher the line screen (anilox cell density), the more subtle the print and better detail. Cheap anilox = thicker print, less detail. Premium anilox = sharper lines, better stroke, higher image quality. This is a parameter that is not visible in the specification, but is visible to the naked eye on the product.

Plate Technology—HD Flexo. Traditional flexo plates provide printing with limited resolution. HD flexo (high-definition) plates allow printing with resolution close to offset printing—i.e., much better detail, better tonal transitions, photorealistic images on packaging. At Kablonex, we use Politex Full HD technology on premium lines, which provides significantly higher image quality than the market standard.

Film Shrinkage and Prepress Compensation. This is a parameter that upsets every brand manager on the first implementation. Film after thermal shrinkage (NEX-SHRINK) or elastic shrinkage (NEX-HOOD) changes dimensions. A print designed at 1:1 scale will be distorted after shrinking—a round logo will be oval, a square QR code will not scan. The print must be designed with shrinkage compensation. This requires experienced prepress and designer-printer communication. Skipping this step is a classic mistake, the consequence of which is visible only after the first production batch.

Water-Based vs. Solvent-Based Inks. I have already mentioned this, but it is worth repeating in the context of quality. Water-based inks provide more subtle transitions, better color fidelity, and are safe for food contact applications. Solvent-based inks dry faster and are cheaper, but provide poorer color quality and impose regulatory restrictions. At Kablonex, we use water-based inks as standard—this is a conscious decision that costs more in equipment, but provides significantly lower CO2 footprint (~4 kg CO2e/m² instead of 12–15) and full compliance with European chain requirements.

These four parameters together—anilox, plate, shrinkage compensation, inks—determine whether 10 colors look like 10 colors, or like 4 with extras. Without the right technology, the number of colors alone means little.

4-Question Checklist—Does Your Product Need 10 Colors

Before you commission a packaging redesign or start talking to a printer, answer four questions. Honestly.

Question 1: Does Your Product Compete Visually on the Retail Shelf? If yes (FMCG, products on retail chain shelves)—proceed to question 2. If no (B2B, industrial products, bags, pallets)—10 colors is overkill. Stay with 4–6.

Question 2: Does the Brand Book Require Pantones or Spot Colors (Opaque White, Spot Varnish, Metallics)? If yes—10 colors will pay off. CMYK simply will not reproduce a Pantone. If no—6 colors are sufficient, provided you have good film and inks.

Question 3: Do You Export to Chains with Rigorous Brand Compliance (Germany, UK, Scandinavia)? If yes—10 colors is not an option, it is a requirement. German and British chains expect full compliance with the supplier’s brand book, regardless of the manufacturer’s marketing self-identification. If no—you can afford 6.

Question 4: Are You Planning a Visual Identity Refresh Within 12 Months? If yes—design the rebranding for 10-color technology, because otherwise in a year you will return with a request to redo everything. If no—maintain the current standard, optimize quality within the existing number of colors (anilox, plate, inks).

Sum up the answers.

3+ “yes”: 10 colors pay off. Do not postpone the decision, the competition will overtake you.

1–2 “yes”: 6 colors + good film + water-based inks are sufficient. Invest in quality within the existing number of colors, not in the number of colors.

0 “yes”: Stay with 4 colors, optimize unit price, invest the saved money in other areas of marketing.

Four questions, about half an hour of brand manager work, and the decision stays with you for years.

Does your packaging look worse than the competition on the shelf, despite similar price? Do German chains reject your product due to brand compliance? Does the brand manager say “CMYK is enough,” while sales in Germany have been declining for the second quarter in a row?

At Kablonex, we have both flexo CI printing systems: in-line up to 6 colors (NEX-HOOD NHD, ideal for pallet branding) and standalone up to 10 colors on 4 printing machines (Politex Full HD, up to 1800 mm width, 400 m/min). Water-based inks as standard (~4 kg CO2e/m² vs. 12–15 for solvent-based). Machine validation for the client’s specific application. 55 years of experience, BRC, ISCC PLUS, EcoVadis.

Expect: full compliance with brand book on packaging, premium look on retail shelf, lower CO2 footprint reportable under PPWR, ready path to German and British chains.

Send brand book specification and sample packaging. We respond the same business day—a technology advisor will contact you and present a printing system recommendation for your product.

Artykuł When It’s Worth Investing in 10-Color Flexo Printing for Packaging. A Guide for Marketing Directors and Brand Managers pochodzi z serwisu Kablonex.

W ostatnich 25 latach branża folii opakowaniowych przeszła technologiczną rewolucję: od folii mono warstwowej, przez konstrukcje 3-warstwowe, po dziś już niemal standardowe układy 5-warstwowe. W Kablonex obie te technologie pracują u nas równolegle – bo każda ma swoje miejsce, swojego klienta i swoją ekonomię.

In this article, I will break this down. Specifically, from a business perspective, without marketing fluff.

What you will read about:

• What exactly is multilayer extrusion and why it’s not a “one-pot blend”
• What real benefits come from transitioning from monolayer to 3 layers — and what research says about the limits of this technology
• Why 5 layers represent a qualitative leap, not just “two more layers”
• When 3 layers are optimal, and when you need 5 — from the perspective of total cost, not film price
• How this choice impacts recycling, ESG, and compliance with PPWR
• What this means in practice for your packaging line

1. Ekstruzja wielowarstwowa – co to właściwie jest

Wielu klientów myśli o folii wielowarstwowej jak o „cieście francuskim” – kilka warstw foliowych sklejonych ze sobą. To błąd.

In the blown film co-extrusion process, each layer is formed simultaneously, at the same moment, in a single die head. We have several separate extruders, each processing a different raw material (or blend), and the molten polymer streams only combine in the die head, forming a single coherent structure. Blowing and cooling occur in the final, multilayer configuration.

This is a crucial difference:

At Kablonex, we work with 1–5 layers, thicknesses from 16–250 µm, and widths up to 3,000 mm — which gives us full structural flexibility within a single technology.

2. Why 3 Layers Changed the Industry

Blown film co-extrusion appeared commercially in the late 1960s (Dow launched its first 3-layer lines for Oscar Mayer in 1967 for bacon packaging), and over the next two to three decades, it became a market standard. For the flexible packaging industry, this was the first real structural revolution — it allowed manufacturers to separate functions into different film layers instead of seeking a compromise in a single formulation.

W Polsce ten skok technologiczny dokonywał się z opóźnieniem względem zachodnich liderów. W Kablonex pierwsza linia do produkcji folii 3-warstwowej weszła na halę produkcyjną pod koniec lat 90., otwierając firmę na zaawansowane segmenty opakowań. Linia 5-warstwowa pojawiła się dopiero po 2010 roku — równolegle z uruchomieniem własnego zakładu recyklingu.

Logic of 3-layer construction (A/B/A or A/B/C arrangement)

• Outer layer (A) — responsible for stiffness, optical parameters, printability, temperature resistance
• Middle layer (B) — mechanical carrier, space for recyclate (PCR), cost regulator
• Inner layer (A or C) — sealing layer (hot-tack, SIT, peel)

What did this bring to the market? Since its introduction, 3-layer co-extrusion has significantly improved the mechanical properties of films compared to films of the same composition made in a monolayer construction.

In practice, this means lower grammage with the same strength, better control over sealing, and the ability to use cheaper raw materials in the middle layer without losing performance parameters.

But 3 Layers Have a Ceiling

And here’s where it gets interesting. In recent years, it has become clear that the limit of maximum mechanical properties achievable in 3-layer films has been reached in many applications — even with the use of the latest polyolefin resins.

In other words: further optimization of the 3-layer formulation ceased to yield results. To go higher, the architecture needs to change.

3. What Real Benefits Come from Transitioning from 3 to 5 Layers

This is not about “adding two layers for effect.” It’s a completely different construction logic.

5-layer architecture (typically A/B/C/B/A or A/B/C/D/E)

In a 5-layer system, we have two additional functional layers at our disposal — most often called sub-skin layers — which act as bridges between the outer layers and the core. This allows for:

• Better matching of raw materials in each layer to its specific function
• Thinner distribution of expensive components (e.g., metallocenes, functional additives)
• Introduction of a barrier layer (EVOH, PA) without compromising sealability
• Increasing the thickness of the middle layer with PCR without losing surface properties

What Science Says

5-layer films have existed for many years, but initially, they were mainly used to create structures with a barrier layer from non-polyolefin raw materials. The die heads used had very thin core layers because barrier resins are relatively expensive. Purely polyolefin films produced on such equipment did not show significant advantages over 3-layer counterparts.

This has changed. Modern 5-layer die heads are designed with a more balanced distribution of layer thicknesses, which, according to patent and review studies, allows for significant improvements in mechanical properties compared to the best 3-layer films — even when both structures are based on the same raw materials.

In Numbers — What Exactly Improves

According to aggregated industry data, multilayer systems produce films with better aesthetics and functionality, achieving 85–90 gloss units (GU) compared to 40–60 GU in monolayer. Co-extruded surface layers also improve slip parameters (coefficient of friction 0.2–0.3) and reduce haze below 5%.

In the context of specific food applications, 5-layer structures with EVOH (PE/PE/Tie/EVOH/Tie/PE/PE extended to 7 layers) have allowed oxygen permeability to be reduced to values below 10 cm³/m²/day while maintaining high mechanical parameters of PE film. This is the level that determines whether frozen foods, aged cheeses, or vacuum-packed meat will withstand their declared shelf life.

4. When 3 Layers Are Enough, and When You Need 5

This is a question every product manager and procurement professional in a packaging company should ask themselves. The answer depends not on the price of the film, but on the total cost of your process.

3 layers are optimal when:

• The application does not require a gas barrier (most industrial, technical, palletizing applications)
• The packaging line operates stably, without temperature bottlenecks
• The product does not require a long shelf-life
• Volume is very high, and margins are low — and every penny per kilogram counts in the P&L
• The film is dedicated to a process with low tolerance for contamination within the seal

5 layers are justified when:

• Products sensitive to oxygen, moisture, or aromas are packaged (frozen foods, coffee, cheeses, meat)
• Seal process stability is critical under contamination conditions (dust, oil, plasma)
• The customer needs a wide sealing window (hot-tack) and reduced initiation temperature (LOW SIT)
• The application requires a combination of properties that 3 layers cannot reconcile (e.g., high gloss + thermal resistance + low SIT)
• The company’s ESG strategy assumes an increase in PCR content without losing surface properties
• The scale of production is large enough that even a 1–2% reduction in line downtime yields six-figure annual savings

Decision Framework — Total Cost, Not Film Price

A 5-layer film will usually be more expensive per kilogram. But the true calculation looks different:

Actual cost = (film price × consumption)

+ (downtime cost × frequency of sealing failures)

+ (complaint cost × defect rate)

+ (cost of lost orders × OTIF gap)

In our operational data, we see that customers who switched from 3 to 5 layers for FFS and lamination applications report a reduction in micro-downtime of 15–30%. For a continuously operating line, this is a return on investment measured in weeks, not years.

5. Recykling i ESG – gdzie 5 warstw daje przewagę regulacyjną

This is a topic that most buyers don’t have on their radar yet, but it will soon impact their P&L: PPWR (Packaging and Packaging Waste Regulation).

Traditional multi-material laminates are problematic for recycling. Co-extruded mono-PE constructions — regardless of the number of layers — are recyclable within the PE stream.

Research reveals an interesting fact. In studies on five-layer co-extruded polyethylene film LLDPE/mPE/PVA/mPE/LLDPE, after four recycling cycles, longitudinal tensile strength decreased from 29.66 MPa to 21.97 MPa, and transverse from 24.9 MPa to 19.22 MPa — meaning the film retains good mechanical properties even after recycling.

This means that a well-designed 5-layer construction can:

• Meet PPWR requirements (recyclability, PCR content)
• Retain performance properties after recycling
• Allow for the introduction of 30%+ PCR in the middle layer without compromising the sealing layers

This is not “eco storytelling.” This is a real competitive advantage — especially with customers in DACH, Scandinavia, and Benelux, where large retailers are already auditing packaging suppliers for PPWR compliance.

6. Co to znaczy w praktyce – perspektywa Twojej linii

Finally, let’s move away from polymers and return to what truly interests production.

3-layer film means for your line:

• A proven, stable material for most standard applications
• Good price/performance ratio where there are no bottlenecks
• A solid base that won’t surprise you positively, but also not negatively

5-layer film means for your line:

• Wider process window (greater tolerance to temperature fluctuations)
• More stable sealing even with contaminants in the sealing area
• Better hot-tack parameters — important for fast FFS lines
• Ability to package demanding products that you previously avoided
• An argument for your end-customer clients regarding ESG

Instead of a Summary

The choice between 3 and 5 layers is not a technical decision. It is a business decision — about how your company wants to compete in the next 5 years. Whether we play on unit cost or process stability and compliance.

There is no single right answer. There is only the right answer for your specific application, line, and end customer.

If you want to discuss which film construction actually makes sense for your process — with a total cost calculation, not just the price per kilogram — contact our technological team. The first conversation usually takes 30 minutes, during which we can tell you if it’s even worth exploring the topic further.

Bo lepiej szybko stwierdzić, że 3 warstwy w zupełności wystarczą, niż przepłacić za 5, których nie potrzebujesz. I odwrotnie — lepiej zainwestować w 5 warstw, niż latami tracić na przestojach linii.

About the Author

Oskar Nawrocki — CEO Kablonex, producenta folii PE i PP z ponad 55-letnią tradycją. Kablonex obejmuje pełen łańcuch wartości: ekstruzję (1–5 warstw, do 1000 kg/h), druk flexograficzny do 10 kolorów, konfekcję oraz własny zakład recyklingu (POD ECO). Firma posiada certyfikacje BRC, ISO i EcoVadis, dostarcza folie do klientów w Polsce i Europie, ze szczególnym naciskiem na rynki DACH. Strategia firmy łączy klasyczną solidność produkcyjną z transformacją w kierunku circular economy — z wykorzystaniem technologii 5-warstwowej i recyklatu PCR jako kluczowych dźwigni rozwoju.

Jeśli chcesz porozmawiać o tym, jak dobrać konstrukcję folii do Twojej linii pakującej — napisz na ask@kablonex.com.pl.

Scientific and Industry Sources

1. Multilayer polyolefin blown film — patent US 9,126,269 (2010) — analysis of the limits of mechanical properties of 3-layer films and the potential of 5-layer constructions
2. Stieglitz M., Hopmann C., Leuchtenberger-Engel L., Junge H. (2025) — Correlation between process conditions and mechanical film properties in foamed multilayer blown films, Journal of Plastic Film & Sheeting
3. Guleria D., Edeleva M., Vervoort S. et al. (2025) — Impact of molecular architecture and draw ratio on enhancement of targeted mechanical properties of MDO polyethylene films, Journal of Plastic Film & Sheeting
4. Borreani G., Tabacco E. (2014) — studies on EVOH/PE structures in 5–7 layer films for barrier applications (cited from ScienceDirect, Barrier Film overview)
5. Recyclable Mono-Material Polyethylene Functional Film (2024) — PMC, NIH — studies on the retention of properties of 5-layer PE film after recycling cycles
6. Adam et al. (2025) — Recycling of Multilayer Polymeric Barrier Films, Macromolecular Materials and Engineering

Zobacz, jak to wygląda w Twojej branży: Drukarnie i konwerterzy i Nawozy i chemia rolnicza. Na każdej stronie: co się psuje, co liczymy zamiast ceny za kg i wdrożenia z liczbami.

Artykuł Multilayer Extrusion — How 3 and 5 Layers Change Film Properties pochodzi z serwisu Kablonex.

A producer of irregularly shaped frozen fruit (Poland and DACH) had bags cracking systematically in deep freezing and during logistics operations in cold storage. A dedicated multilayer formulation with mLLDPE, matched to the product shape and to sealing on the customer’s line, brought zero cracks at temperatures down to -25 and -30 °C.

01 Customer

Poland and DACH. A producer of frozen fruit with irregular geometry, packed in characteristic blue bags.

02 Challenge

The irregularly shaped fruit systematically tore the packaging: in deep freezing and during logistics operations in cold storage.

An irregular product shape means point stresses, and at -25 °C polyethylene loses its flexibility and cracks instead of deforming.

03 Solution

• Formulation: dedicated, multilayer.
• Metallocenes: mLLDPE in the formulation.
• Low-temperature flexibility: components that increase flexibility at low temperatures.
• Fit: matched to the specific product geometry and the sealing parameters on the customer’s line.

04 Results

• Cracking: zero cracks at temperatures down to -25 and -30 °C.
• Seal: stable in cold conditions.
• Cold chain: fewer complaints and losses.

05 What this means for you

If your product has sharp edges or an irregular shape, standard freezer film is working at its limit. The problem is solved by choosing the right low-temperature flexibility, not by adding thickness.

Artykuł Frozen fruit producer: no more bag cracking at -25 °C pochodzi z serwisu Kablonex.

A large laminate converter from the Baltic region, supplying packaging for butter and cheese, wanted to move away from a paper, aluminium, PE laminate without losing the paper look, the grease barrier and the ability to wrap the product into blocks. A single paper-like film with chalk, 55 µm as standard, replaced three laminate layers: no aluminium and no paper.

01 Customer

Baltic region. A large laminate converter, food packaging: butter and cheese. The customer had historically specialised in paper plus aluminium plus PE laminates.

02 Challenge

The customer wanted to simplify the pack construction and move away from aluminium, but had to keep everything the laminate provided: the paper look, the grease barrier and the ability to wrap the product into blocks.

Removing aluminium usually means losing the barrier.

03 Solution

• Base: a PE-based paper-like film.
• Composition: a high share of mineral components (chalk) and a share of bio-based raw materials.
• Thickness: adapted to the customer’s block-wrapping process, 55 µm as standard.
• Construction: one film instead of three laminate layers, no aluminium and no paper; the high mineral content reduces the amount of polymer in the pack.

04 Results

05 What this means for you

An aluminium laminate is convenient technically, but it means three materials in one pack. If you pack butter, cheese or fats and want to simplify your pack structure, this is a route that does not require changing your packing machine.

Artykuł Large Baltic converter: paper-like film instead of a paper, aluminium, PE laminate pochodzi z serwisu Kablonex.

A toilet paper and towel manufacturer wanted to reduce the plastic footprint of its packaging and introduce a high share of recycled content without losing runnability on the packing line. A new multi-layer formulation made it possible to go from 35-40 µm to 28 µm with 35% PCR in the standard line and up to 55% PCR in the premium variant, with runnability maintained.

01 Customer

A hygiene products manufacturer in Central Europe: toilet paper and towels. It previously packed using a classic, homogeneous technology optimised for easy opening.

02 Challenge

The goal: a smaller plastic footprint without losing runnability on the packing line and without logistics risk, plus a high recycled content.

The difficulty is that high PCR and thin film impair exactly the parameter that is critical in this application: tear resistance when the pack is carried.

03 Solution

• New construction: a new multi-layer formulation with enhanced mechanical properties instead of the homogeneous technology.
• Downgauging: from 35-40 µm to 28 µm.
• Recycled content: 35% PCR in the standard line and up to 55% PCR in the premium variant, introduced together with the downgauging.
• Printing: integration with NEX PRINT, flexo CI in up to 10 colours, for two of the customer’s product lines.

04 Results

05 What this means for you

55% recycled content in 28 µm films is a level that most of the market does not reach even with thicker constructions. If you have a PCR target written into a contract with a retail chain, this is a benchmark.

Artykuł Toilet paper manufacturer: from 35 to 28 µm with 35-55% PCR pochodzi z serwisu Kablonex.

A global furniture chain was replacing film logistics sleeves with a glued paper solution, in line with the group’s ESG policy. The condition was full logistics functionality. A glued paper sleeve formed in our own plant replaced the film without any loss of that functionality, and the pack goes into the standard paper recycling stream.

01 Customer

Poland and Scandinavia. A global furniture chain which, in line with the group’s ESG policy and consumer expectations, was replacing traditional film logistics sleeves with a glued paper solution.

02 Challenge

The condition: the paper sleeve must keep full logistics functionality.

Paper does not forgive what film does: it does not stretch, it has a fibre direction and it needs a glued seam.

03 Solution

• Construction: a glued paper sleeve adapted to the customer’s logistics process.
• Production: formed in our own plant using paper converting technology.
• Raw material: paper from certified sources.
• Recycling: adhesive and construction optimised for recycling in the standard paper stream.

04 Results

• Film sleeve replaced with paper: without loss of logistics functionality.
• ESG: full compliance with the customer’s ESG policy.
• Recycling: the pack goes into the standard paper recycling stream.

05 What this means for you

Moving from film to paper is not a change of material, but four decisions at once: printing, forming, gluing and working with your line. That is where these projects break. With us, all four are under one roof.

Artykuł Global furniture chain: a paper sleeve instead of a film sleeve pochodzi z serwisu Kablonex.

A bread producer supplying the private label of a large retail chain was looking for a replacement for 30 µm PP wicket bags, which cracked during frozen transport. A dedicated PE formulation with a polyolefin blend made it possible to switch to 18 µm film: around 40% less material while keeping the look on the shelf and runnability on the wicket lines.

01 Customer

A Polish bread producer that supplies the private label of a large retail chain. It packs bread in wicket bags.

02 Challenge

The customer was looking for an alternative to 30 µm polypropylene wicket bags. The PP cracked during frozen transport.

The new packaging had to meet three conditions: transparency and the look on the shelf retained, stability on the wicket line, and resistance at low temperatures. The retail chain does not accept packaging through which the product cannot be seen.

03 Solution

• Material: a dedicated PE formulation with a polyolefin blend for bread packaging.
• Thickness: 18 µm PE film instead of 30 µm PP.
• Line: runnability on the wicket lines retained.
• Shelf: packaging appearance retained.

04 Results

05 What this means for you

Switching from PP to PE sounds like a step back in terms of stiffness. With the right polyolefin blend it is the other way round: you get thinner packaging that does not crack in frost and goes into the PE recycling stream. This is the strongest downgauging argument in our entire portfolio.

*Around 40% is the difference in film thickness: 30 → 18 µm. The case study is anonymised.

Artykuł Bakery chain: 18 µm PE instead of 30 µm PP, 40% less material pochodzi z serwisu Kablonex.

A wood pellet and charcoal manufacturer wanted to take as much film as possible out of the bag on its fastest FFS line, without losing a cycle and without the risk of punctures from sharp pellet fractions. NEX-BAG FFS HQ in a 5-layer construction with mLLDPE made it possible to go from 80 to 50 µm, a reduction of 37.5%, with line speed unchanged.

01 Customer

A wood pellet and charcoal manufacturer in Poland. It packs on the fastest FFS line in its portfolio.

02 Challenge

The brief was to take as much film as possible out of the bag without losing a single cycle on the line and without risking punctures from sharp pellet fractions.

These three conditions usually rule each other out, because thinner film means a smaller puncture margin and a narrower sealing window.

03 Solution

• Film: NEX-BAG FFS HQ 50 µm in a 5-layer construction with mLLDPE.
• Selectively designed layers: instead of slimming all layers evenly, the outer layers took over puncture resistance and the middle layer shed mass.
• Thickness: down by 37.5%.

04 Results

05 What this means for you

If you pack bulk material with sharp fractions and have been told that at your line speed it is not possible to go below 70-80 µm, this case shows that it is. The condition: the film has to be designed for your machine, not picked from a catalogue.

Artykuł A 50 µm pellet bag instead of 80 µm: one of the thinnest on the European market pochodzi z serwisu Kablonex.

A British abrasives manufacturer needed an FFS bag with 30% PCR, a width outside the standard specification of production lines and a smaller CO₂ footprint for the whole package. The 5-layer NEX-BAG FFS HQ construction delivered a bag outside the typical width specification, with 30% PCR and full strength for an abrasive product, and flexo CI printing with water-based inks on the Kablonex line significantly reduced the CO₂ footprint compared with solvent-based printing.

01 Customer

An abrasives manufacturer in the United Kingdom. It packs an abrasive product in FFS bags on its own line, for which it needed a bag with a width outside the standard specification.

02 Challenge

The British market introduced a standard of at least 30% PCR in film packaging for chemicals and abrasive materials. In addition, the customer needed a bag with a width outside the standard specification of production lines and a reduction in the CO₂ footprint of the whole package.

Abrasive material is also one of the most aggressive loads for film.

03 Solution

• Construction: the 5-layer NEX-BAG FFS HQ made it possible to produce a bag outside the typical width specification.
• Recycled content: 30% PCR with full strength for an abrasive product.
• Printing: flexo CI with water-based inks, on the Kablonex line.

04 Results

• 30% PCR: compliance with the British requirement.
• Format: a bag outside the market standard, matched to the customer’s existing line.
• CO₂ footprint: a significant reduction in CO₂ footprint compared with solvent-based printing.

05 What this means for you

If a supplier has told you that your format is “outside the specification”, ask us about it. A non-standard width is usually not a technological limitation, but an organisational one.

Artykuł British abrasives manufacturer: a narrow FFS bag with 30% PCR and water-based ink printing pochodzi z serwisu Kablonex.