Case study

Recyclable mono-PE cheese packaging on HFFS lines

  • Reading time 2 min

  1. Project objective

    Develop and validate a recycle-ready mono-PE packaging solution for cheese products, designed for HFFS machines, capable of improving recyclability and reducing weight compared with conventional rigid tray solutions, while maintaining equivalent shelf-life performance.

  2. Year

    2025

  3. Lab/Division

    OPENLab site
    Lugano
     
    IMA division/company involved
    IMA Ilapak Lugano
     
    Partners involved
    ExxonMobil, Alpine

Project overview

Collaboration across the packaging value chain is essential to develop innovative materials and processes aligned with sustainability requirements.
In this project, a mono-PE structure with high gas-barrier properties was engineered and manufactured by ExxonMobil and Alpine, then converted into pouches on an IMA Ilapak HFFS line specifically configured for this application.

Material quality optimisation and sealing profile adjustments were developed through multiple trial sessions. These activities enabled the production of fully gas-tight packs at industrial speed, while maintaining performance comparable to non-recyclable structures.

Key results

  1. Weight reduction

    Over 60% weight savings compared with rigid thermoformed trays.

  2. Design for recyclability

    With more than 90% PE content, the package can meet design-for-recyclability criteria by keeping the EVOH barrier layer below the 5% threshold.

  3. Oxygen barrier performance

    MDO technology enhances the efficiency of the ultra-thin EVAL™ EVOH layer (2 μm).
    Oxygen transmission rate (OTR): < 0.5 cc/m²·day, suitable for typical cheese packaging.

  4. Hermetic sealing and processability

    Reliable performance on a full-scale HFFS packaging line, achieving consistent hermetic sealing and smooth machine conversion at 130 packs/minute.

  5. Optical properties

    Low haze and high product visibility enhance shelf appeal.
    Total haze: 6.9% for the MDO PE substrate film.