Ink manufacturer Siegwerk, polyolefin specialist Borouge, and Thailand-based packaging manufacturer TPN Food Packaging have jointly developed a fully recyclable, mono-material stand-up pouch designed to meet the performance and sustainability requirements of oxygen-sensitive dry goods such as nuts and pet food.

The new pouch, now in commercial production, is the first output from a broader collaboration between the three companies and is positioned as a viable, circular alternative to conventional multi-material flexible packaging.

The pouch features a full polyethylene (PE) triplex laminate structure, making it suitable for existing recycling streams. It combines Borouge’s Borstar FB5600, a bimodal high-density polyethylene, with Anteo PE sealant film, which enables fast sealing at lower temperatures. Siegwerk has supplied an oxygen barrier coating, Cirkit OxyBar BC1582, and a de-inking primer, Cirkit ClearPrime. Together, these components deliver low oxygen transmission rates while ensuring that inks can be efficiently removed during recycling to obtain uncoloured recycled PE suitable for future packaging applications.

Siegwerk said the new mono-material pouch is suitable for both flexo and gravure printing.

The pouch was produced by TPN using its rotogravure printing lines and is capable of being manufactured at commercial speeds. The printed MDO-PE layer provides high stiffness and flatness at speeds of around 200 metres per minute. Despite being made from a single material family, the pouch maintains the stiffness, mechanical strength, seal integrity, and printability required for use as a drop-in replacement for traditional laminates, explained Siegwerk.

Designed with circularity in mind, the pouch enables 100% recyclability while maintaining performance. Its development demonstrates the potential of combining material science, ink formulation, and production expertise to create sustainable packaging.

Dr Stephane Bertaux, head of brand owner collaboration and sustainability for Southeast Asia at Siegwerk Thailand, commented: “This development is a great example of how collaboration between different areas of expertise and knowledge can achieve the production of high-performance mono-material packaging that is de-inkable and fully recyclable. This project demonstrates how cross-industry collaboration can produce scalable, sustainable packaging solutions.”