Borealis and Comexi introduce two new sustainable flexible packaging solutions

A fully recyclable PE laminate with 35% PCR and BorShape™ booster

The first solution is a full polyethylene (PE) laminate containing 35% PCR content from Ecoplast, a Borealis Group member and a leading plastics recycler in Austria. The PCR material is refined for low gel content, ensuring smooth converting, excellent optical quality, and reliable mechanical performance. Its quality is backed by Ecoplast’s EuCertPlast certification, awarded to recyclers who meet the highest standards for processing post-consumer waste.

This lightweight laminate’s performance is further improved by the inclusion of BorShape™, Borealis’ mechanical booster, which enables the use of high PCR levels without compromising processability, strength, or durability. The layers are bonded using Comexi’s advanced lamination lines, paired with laminating adhesives optimized for mechanical recycling. The lamination adhesives are supplied by H.B. Fuller, a global leader in adhesive solutions.

Packaging production is optimized through our collaboration with Mespack, an international manufacturer of packaging machinery from primary to secondary packaging. Their horizontal form, fill, and seal equipment ensures efficient and seamless production, enabling global consumer brands to achieve high-quality, sustainable and consistent results with ease. This innovation is further enhanced at the Mespack Innovation Centre, where continuous development and testing push the boundaries of packaging solutions to meet the evolving needs of the market. Additionally, Mespack is a leader in manufacturing machines designed to work with a variety of recyclable materials. Mespack supports their partners and clients in overcoming this challenge, helping them stay at the forefront of the market and drive sustainable innovation.

To meet brand owners’ design needs, the solution makes use of Comexi’s flexographic solvent-based reverse printing technology, which delivers sharp, vibrant visuals. The structure is protected by a laminated film layer—essential when using solvent-based inks—which enhances gloss, mechanical resistance, and thermal resistance.

Additional functionality is provided by a "Press to Close Zipper" from ELPLAST, a global leader in high-quality zipper solutions. Even with these advanced features, the laminate remains a monomaterial PE structure, making it fully recyclable.

A simplified monomaterial PE structure with 40% PCR

The second solution offers a different approach. It’s a fully recyclable, single-web monomaterial PE structure with 40% PCR content, also supplied by Ecoplast. By eliminating the need for lamination, this simplified structure reduces processing complexity while maintaining excellent mechanical properties.

Ecoplast PCR is once again paired with BorShape, ensuring excellent processability, strength, and flexibility, even with higher recycled content levels. Mespack’s advanced pouch-making equipment supports efficient production while also delivering superior functionality and performance.

Surface printing, enabled by Comexi’s F2 Hybrid EB press, reduces solvent use and emissions while delivering high-quality visuals that meet brand owners' and consumer expectations. In place of solvent-based inks, this solution uses Electron Beam (EB) inks along with an EB overprint varnish, which provides gloss, mechanical resistance, and thermal resistance. As a result, the structure doesn’t need to be laminated, making it more sustainable.

These two solutions reflect our EverMinds™ commitment to advancing circularity through collaboration. They also showcase the versatility of Borealis’ advanced polyethylene materials, delivering packaging that addresses the needs of consumers, brand owners, and the planet alike.