{"id":2066,"date":"2026-05-22T13:23:55","date_gmt":"2026-05-22T11:23:55","guid":{"rendered":"https:\/\/kablonex.pl\/bez-kategorii\/downgauging-of-hygiene-film-from-35-%ce%bcm-to-28-%ce%bcm-35-55-pcr-for-a-toilet-paper-manufacturer-premium-line\/"},"modified":"2026-10-08T12:13:47","modified_gmt":"2026-10-08T10:13:47","slug":"downgauging-of-hygiene-film-from-35-%ce%bcm-to-28-%ce%bcm-35-55-pcr-for-a-toilet-paper-manufacturer-premium-line","status":"publish","type":"post","link":"https:\/\/kablonex.pl\/en\/case-study\/downgauging-of-hygiene-film-from-35-%ce%bcm-to-28-%ce%bcm-35-55-pcr-for-a-toilet-paper-manufacturer-premium-line\/","title":{"rendered":"Toilet paper manufacturer: from 35 to 28 \u00b5m with 35-55% PCR"},"content":{"rendered":"\n<div class=\"kx-article\">\n\n  <p class=\"kx-lead\">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 \u00b5m to 28 \u00b5m with 35% PCR in the standard line and up to 55% PCR in the premium variant, with runnability maintained.<\/p>\n\n  <div class=\"kx-summary\">\n    <div class=\"kx-label\">In brief<\/div>\n    <ul>\n      <li><b>Customer:<\/b> a hygiene products manufacturer in Central Europe: toilet paper and towels.<\/li>\n      <li><b>Problem:<\/b> high PCR and thin film both reduce tear resistance when the pack is carried, which is the critical parameter in this application.<\/li>\n      <li><b>Solution:<\/b> a new multi-layer formulation with enhanced mechanical properties and NEX PRINT printing, flexo CI in up to 10 colours.<\/li>\n      <li><b>Result:<\/b> from 35-40 \u00b5m to 28 \u00b5m, 35% PCR as standard and up to 55% PCR in the premium variant, packing line runnability maintained.<\/li>\n    <\/ul>\n  <\/div>\n\n  <div class=\"kx-stats\">\n    <div><b>28 \u00b5m<\/b><span>instead of 35-40 \u00b5m<\/span><\/div>\n    <div><b>35% PCR<\/b><span>in the standard line<\/span><\/div>\n    <div><b>up to 55%<\/b><span>PCR in the premium variant<\/span><\/div>\n    <div><b>10<\/b><span>flexo CI print colours<\/span><\/div>\n  <\/div>\n\n  <h2><span class=\"kx-num\">01<\/span> Customer<\/h2>\n\n  <p>A hygiene products manufacturer in Central Europe: toilet paper and towels. It previously packed using a classic, homogeneous technology optimised for easy opening.<\/p>\n\n  <h2><span class=\"kx-num\">02<\/span> Challenge<\/h2>\n\n  <p>The goal: a smaller plastic footprint without losing runnability on the packing line and without logistics risk, plus a high recycled content.<\/p>\n\n  <p>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.<\/p>\n\n  <h2><span class=\"kx-num\">03<\/span> Solution<\/h2>\n\n  <ul>\n    <li><b>New construction:<\/b> a new multi-layer formulation with enhanced mechanical properties instead of the homogeneous technology.<\/li>\n    <li><b>Downgauging:<\/b> from 35-40 \u00b5m to 28 \u00b5m.<\/li>\n    <li><b>Recycled content:<\/b> 35% PCR in the standard line and up to 55% PCR in the premium variant, introduced together with the downgauging.<\/li>\n    <li><b>Printing:<\/b> integration with NEX PRINT, flexo CI in up to 10 colours, for two of the customer&#8217;s product lines.<\/li>\n  <\/ul>\n\n  <h2><span class=\"kx-num\">04<\/span> Results<\/h2>\n\n  <table class=\"kx-spec\">\n    <caption>Before and after<\/caption>\n    <tbody>\n      <tr><th scope=\"row\">Film thickness<\/th><td>35-40 \u00b5m \u2192 28 \u00b5m<\/td><\/tr>\n      <tr><th scope=\"row\">Construction<\/th><td>homogeneous \u2192 multi-layer with enhanced mechanical properties<\/td><\/tr>\n      <tr><th scope=\"row\">PCR content<\/th><td>35% as standard, up to 55% in the premium variant<\/td><\/tr>\n      <tr><th scope=\"row\">Packing line runnability<\/th><td>maintained<\/td><\/tr>\n      <tr><th scope=\"row\">Printing<\/th><td>up to 10 colours on both product lines<\/td><\/tr>\n    <\/tbody>\n  <\/table>\n\n  <h2><span class=\"kx-num\">05<\/span> What this means for you<\/h2>\n\n  <p>55% recycled content in 28 \u00b5m 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.<\/p>\n\n  <div class=\"kx-link\"><b>FMCG<\/b><a href=\"https:\/\/kablonex.pl\/en\/industries\/fmcg\/\">Packaging films for FMCG and food<\/a><\/div>\n\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>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 \u00b5m to 28 \u00b5m with 35% PCR in the standard line and up to [&hellip;]<\/p>\n","protected":false},"author":5,"featured_media":2834,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_kad_blocks_custom_css":"","_kad_blocks_head_custom_js":"","_kad_blocks_body_custom_js":"","_kad_blocks_footer_custom_js":"","footnotes":""},"categories":[26],"tags":[],"class_list":["post-2066","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-case-study"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.8 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Toilet paper film: 28 \u00b5m with up to 55% PCR | Kablonex<\/title>\n<meta name=\"description\" content=\"Toilet paper packaging film: from 35-40 \u00b5m to 28 \u00b5m with 35% PCR, up to 55% PCR in the premium variant. 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