What are mono-materials?

A mono-material is a product made from a single type of material, such as paper, plastic, or metal. These materials can be modified to achieve different strengths or flexibility without changing their core composition. Since mono-materials do not require component separation, recycling becomes faster, more efficient, and less energy-intensive.

What are examples of mono-materials? 

The main types of mono-materials used in packaging include:

• Polypropylene (PP): Polypropylene (PP) is a common choice for packaging due to its strong sealing capabilities and durability. It is used for durable pouches and containers that are easier to recycle. For example, Dai Nippon Printing’s PP-based packaging meets high barrier needs while maintaining recyclability.
• Polyethylene (PE): Polyethylene (PE), which includes high-density polyethylene (HDPE) and low-density polyethylene (LDPE), is commonly used in flexible packaging like films and bags. PE mono-material films offer moisture resistance, which makes them ideal packaging materials for snack bags and food wraps. 
• Polyethylene Terephthalate (PET): Polyethylene Terephthalate (PET) is commonly used for sturdy packaging, especially in beverage bottles. This is due to its strength and clarity, making it suitable for packaging that faces temperature changes or pressure during transport. It is easily recyclable and often transformed into new bottles or other products.

Why are mono-materials important for the packaging industry?

Here are some of the key reasons that make mono-materials essential for the packaging industry:

• Lowers resource consumption: Mono-materials reduce the number of production steps, which leads to lower resource and energy usage. This efficiency helps companies cut operational costs and minimize environmental impact.
• Reduces manufacturing costs: The simplified production process of mono-materials requires fewer resources, leading to lower manufacturing expenses. This makes them a cost-effective option for businesses looking to optimize their packaging budgets.
• Ensures material availability: Using a single material streamlines the supply chain and minimizes the risk of material shortages. This consistent availability helps manufacturers maintain production schedules without disruption.
• Protects packaged products: Mono-materials offer uniform properties that ensure better structural strength and effective sealing. This helps protect packaged products during transportation, reducing the risk of damage or contamination.
• Improves circularity: Mono-materials support closed-loop recycling systems, promoting recyclable packaging solutions that enable reuse without contamination. This promotes a circular economy and helps companies achieve their sustainability objectives.
• Simplifies recycling: Since mono-materials don’t require separating different polymers, they simplify the recycling process. This increases efficiency in waste management facilities, leading to higher recycling rates.
• Improves product transparency: Clear labeling on mono-material packaging makes it easier for consumers to understand recycling instructions. This improves disposal compliance and also promotes the brand’s eco-friendly image.

What key factors should packaging manufacturers consider?

Before transitioning to mono-material packaging, manufacturers should evaluate the following factors: 

Cost implications

Transitioning to mono-materials often requires new machinery, R&D, and adjustments in production processes, which can increase initial costs. Manufacturers must assess whether the long-term savings from easier recyclability and reduced material waste will offset their upfront expenses.

Optimizing existing equipment

Existing equipment may not be optimized for mono-materials. Current equipment may require modifications to maintain production efficiency and prevent downtime. Mono-materials may require fine-tuning of stiffness, elasticity, and heat-sealing capabilities. 

Supply chain adjustments

Transitioning to mono-materials may involve shifts in sourcing materials, which could affect supplier relationships and logistics. With a focus on single materials, manufacturers must ensure consistent supply to avoid disruptions and maintain steady production flow.

Barrier properties and product protection

Mono-materials may struggle to match the barrier properties (e.g., against moisture or gases) provided by multi-layer structures. Matching it requires additional innovation in material science. Packaging must maintain structural integrity and protection for contents during transport and storage, which may require specialized formulations or coatings.

Can mono-materials solve the global packaging waste crisis?

Mono-material packaging offers a viable path to reducing global packaging waste due to its simpler recycling processes. For instance, the market for mono-material films is expected to grow at a 3.8% CAGR, reaching $70.9 billion by 2025. The growth is driven by regulatory pressure and consumer demand for sustainable packaging materials and solutions.

With advancements in material formulations and barrier properties, mono-materials can improve recyclability without compromising functionality. If the industry addresses technical challenges, mono-materials could significantly reduce the environmental impact of packaging waste.

Stay ahead in mono-material packaging – Access our Intelligence Brief here to read about:

• New guidelines promoting recyclable and sustainable packaging solutions
• Most viable opportunities for growth in mono-material packaging
• ESG goals and how they relate to packaging innovation
• Key research and development focus areas
• Profiles of leading companies and their available solutions