Borealis and Comexi Unveil Innovative, Fully Recyclable Flexible Packaging Solutions with High PCR Content

Borealis and Comexi Unveil Innovative, Fully Recyclable Flexible Packaging Solutions with High PCR Content

(IN BRIEF) Borealis, in partnership with Comexi and other key players, has launched two new flexible packaging solutions for non-food consumer applications that combine high PCR content, full recyclability, and excellent performance. The first solution is a fully recyclable PE laminate with 35% PCR content, enhanced with BorShape™ and bonded using Comexi’s lamination lines and top-grade adhesives. It is designed to offer smooth converting, outstanding optical quality, and reliable mechanical performance. The second solution is a simplified, single-web monomaterial PE structure featuring 40% PCR, which eliminates the need for lamination and simplifies the production process while maintaining high strength and flexibility. Both solutions utilize cutting-edge technologies such as Mespack’s advanced equipment and Comexi’s F2 Hybrid EB printing, ensuring reduced solvent use and high-quality surface printing. These innovative products further Borealis’ commitment to circularity and sustainability, meeting the needs of modern consumer packaging while supporting the company’s EverMinds™ initiative. Statements from Peter Voortmans and Jordi Puig underscore the value-add and collaborative effort behind these advancements.

(PRESS RELEASE) VIENNA, 11-Apr-2025 — /EuropaWire/ — Borealis and Comexi, in collaboration with key value chain partners, have introduced two innovative flexible packaging solutions that combine high levels of post-consumer recycled (PCR) content, full recyclability, and exceptional performance. Designed specifically for non-food consumer packaging, these solutions meet modern design, functionality, and sustainability requirements while advancing circular progress.

The first solution is a fully recyclable polyethylene (PE) laminate that incorporates 35% PCR content supplied by Ecoplast, a leading plastics recycler and Borealis Group member from Austria. This refined PCR material, with low gel content, ensures smooth converting, superior optical clarity, and robust mechanical performance. Its high performance is further enhanced by the inclusion of BorShape™, Borealis’ mechanical booster, which allows for a greater use of PCR without compromising processability or durability. The layers of this laminate are bonded using advanced lamination lines from Comexi and adhesives provided by a global leader in adhesive solutions, ensuring reliable mechanical recycling.

In parallel, the second solution presents a simplified monomaterial PE structure, which is fully recyclable and contains 40% PCR—also sourced from Ecoplast. By removing the need for lamination, this design reduces processing complexity while preserving excellent strength, flexibility, and processability, thanks to the integration of BorShape™. Efficient production of this structure is supported by Mespack’s advanced pouch-making equipment and high-quality surface printing technology via Comexi’s F2 Hybrid EB press. This printing system uses Electron Beam (EB) inks and an EB overprint varnish to yield sharp, vibrant visuals with reduced solvent use and emissions, while maintaining gloss, mechanical resistance, and thermal stability—all without the need for a laminated film layer.

Both solutions highlight Borealis’ commitment to advancing circularity in partnership with industry leaders. They are tailored to meet the high-performance needs of brand owners and consumers while supporting sustainability goals. These innovations contribute to the EverMinds™ ambition of Borealis to foster circularity in packaging and demonstrate the power of collaboration between partners such as Comexi, Ecoplast, and Mespack.

Peter Voortmans, Borealis Global Commercial Director Consumer Products Flexibles, stated, “These two new solutions reflect our commitment to advancing circularity through collaboration, delivering flexible packaging that meets the highest performance standards and supports our sustainability objectives.” Jordi Puig, Comexi Flexo Technical Sales Director, added, “At Comexi, we are proud to lead these innovative solutions with our advanced lamination and printing technologies, proving that sustainability and functionality can go hand in hand.”

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Tel: +43 1 22 400 899
email: media@borealisgroup.com

SOURCE: BOREALIS