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Cardboard and corrugated cardboard Flexible packaging materials
Turnkey R&D service 3D virtual store Logistics cycle simulation Just in time delivery Technological support
Food and Beverage Consumer goods Industrial goods

Enterprise Group "Gotek" developed fully recyclable film ReviAll

Society's demand for environmentally friendly products and materials, reasonable consumption aimed at reducing the negative impact on nature, is constantly growing. This year it was strong supported by the state: with the introduction of amendments to the federal law "On Production and Consumption Waste" the responsibility of packaging manufacturers was expanded, who are now required to ensure its disposal or pay an environmental fee.

At the same time, the domestic flexible packaging market has long been focused on complex combined polymer solutions, practically ignoring the function of packaging recyclability. Manufacturers did not have the technical capabilities to create environmentally friendly mono-materials capable of providing reliable protection for the product throughout its life cycle.

Today, despite the emerging matters about the regulatory process, it is already obvious that non-recyclable flexible packaging is becoming economically unprofitable for all market participants. Taking up this challenge, specialists from "Gotek" Plastics Division created ReviAll - a fully recyclable material structure capable of replacing expensive combined solutions. Dmitry Sokolov, Director of Research and Development of Packaging Materials at "Gotek-Polypack Pereslavl" LLC, told about the company's new development.

Dmitry, why has the production of recyclable film materials become one of the priority areas for "Gotek" Plastics Division?

At present the division annually produces about 35 thousand tons of polymer packaging. This is about 10% of the domestic market and according to our estimates the third place in terms of production capacity in the country. We understand and accept our share of responsibility for the nature integrity and the solution of modern environmental problems. That’s why we spend significant resources on the development of packaging materials that can be used for recycling and at the same time perform their main function of preserving our customers' products at the same high level.

Experts from "Gotek-Polypack Pereslavl" LLC have conducted a full research cycle for a few years and launched industrial production of films suitable for recycling.

Various eco-trends are now all the rage but often the average buyer has little understanding of recycling and ecology. Tell us what is a recyclable film and how did the company's specialists manage to develop this technology?

Standard flexible packaging is usually made of multilayer films consisting of different polymer types. Such materials are widely used in the development of packaging solutions, especially for the food industry, where it is important to create a reliable barrier between the product and environment. However, the presence of different polymers in the packaging prevents its further recycling - such packaging either accumulates in landfills or is burned in special plants what is not rational, you would agree.

To be recycled flexible packaging must consist exclusively of polymers of one group. However, it is very difficult to preserve its functional properties. Bu we succeeded. By means of long laboratory research we developed special materials consisting of one type of polymers retaining all the packaging properties at the same level: they provide long shelf life, withstand special processing conditions, including sterilization and pasteurization of the product at the customer's production facility, and so on. This film can be used to manufacture various packaging solutions: baby food pouches, pet food bags and other types of packaging, without any restrictions.

Now the ReviAll material has passed all tests and has been launched into industrial production.

What projects have already been implemented using this material?

There are many such projects. For example, we are now producing coffee packaging from a fully recyclable film. Previously, in the standard structure, the safety of this product was ensured by aluminum in the composition of the multilayer film, now this need has completely disappeared. The new material perfectly performs the barrier function. We produce packaging for baby food in large quantities, starting with the first complementary food for babies to a wide range of purees and juices. We offer our new ReviAll solution to all customers and are ready to make deliveries from all 3 sites of the division (Gotek-Polypack Pereslavl, Gotek-Polypack (Zheleznogorsk) and Gotek-Polypack Aramil).

When does the "second life" of your packaging begin and what can be made from it?

Polymers that are subject to recycling are specially marked and after primary use are sent to plastic recycling plants. Secondary raw materials obtained from film are the basis for the production of technical parts, pipes, paving slabs and even tableware, toys and souvenirs. It was important for the "Gotek" Group to start working in the direction of recycling and I am sure the company will continue to implement projects in the field of ecology and recycling.

The new development of the Enterprise Group "Gotek" was reported by specialized media. Read the materials on the portals "Unipak", "Russian Food Market" and "Tara i Upakovka", as well as on the "RBK Chernozemye" portal.