ExxonMobil, one of the largest publicly traded international energy companies, uses technology and innovation to help meet the world's growing energy needs. The company recently launched its new ExxonMobil Signature Polymers portfolio brand, which focuses on delivering best-in-class service and partnerships within the polymers industry. ExxonMobil Signature Polymers unifies ExxonMobil's polyolefin products under a single brand, simplifying portfolio navigation and promoting enhanced collaboration across the value chain.

In response to evolving regulations like the European Packaging and Packaging Waste Regulation (PPWR), ExxonMobil Signature Polymers collaborated with Hosokawa Alpine, a leading provider of advanced barrier film extrusion solutions, and IMA Ilapak, a global specialist in horizontal form, fill & seal (HFFS) packaging machinery, to develop a mono-material polyethylene (PE) pouch for cheese packaging designed for recyclability.

This innovative solution replaces conventional multi-material rigid trays and lid films, offering a thinner, recyclable alternative that maintains shelf-life and runs efficiently on HFFS lines.

Using Alpine’s advanced 9-layer barrier blown film line with inline machine direction orientation (MDO) technology, ExxonMobil Signature Polymers resins were used to produce both the MDO PE barrier substrate and the PE sealant film. Alpine’s die head geometry and MDO capabilities enabled the creation of an ultra-thin 2-micron EVOH barrier layer using EVAL™ LT172B, delivering strong oxygen barrier performance.

Key resins used:

• MDO PE substrate film:
  • Exceed™ HD 6107 – optimized for MDO processing
  • Exceed™ Stiff+ m 0238.RA and Exceed™ Flow+ m 0938.RA – enhanced stiffness and tailored mechanical properties 
  • Exceed Stiff+ m 0820.RL – improved process stability
• Sealant film:
  • Exxtra™ Seal POP 2008.RK – low seal initiation temperature and hermetic sealing
  • Exceed Stiff+ m 0820.RL – balanced stiffness and toughness
  • Exceed™ m 2018.RA – ideal for lamination
  • ExxonMobil™ HD 6207FL – stiffness modification
  • ExxonMobil™ LD 07523.AC – enhanced processing stability

The laminate film was reverse printed, laminated, and converted into pouches on IMA Ilapak’s HFFS machine, which supports both conventional and mono-material packaging formats.

“At IMA Ilapak, we have extensive experience in correlation of lab analyses and field testing of a wide range of packaging materials, and we are committed to ensuring they run efficiently on our machines, leveraging innovative technologies whenever needed,” said Davide Paltrinieri, Group Lab Materials Technologist at IMA Ilapak. “Using this tailor-made, high-performance MDO PE laminate, we successfully achieved hermetic sealing at speeds of up to 130 packs per minute on a long-dwell machine with optimized heat-sealing profiles.”

Key results include:

• Weight reduction: Over 60% savings compared to rigid thermoformed trays
• Design for recyclability: >90% PE content with EVOH layer <5%
• Oxygen barrier: OTR < 0.5 cc/m² x day – suitable for cheese packaging
• Hermetic seal: Reliable sealing and smooth conversion on full-scale HFFS lines
• Optical properties: Low haze (6.9%) and excellent product visibility

To check out the full case study, visit here.