ExxonMobil Develops High-Performance, 95% PE Recyclable Thermoformed Packaging

Working with equipment suppliers Hosokawa Alpine, Multivac Group and Eval, ExxonMobil was able to create a fully recyclable 95% PE-based thermoformed package using its latest generations of performance resins along with those of Eval. This innovation aligns with the industry's shift toward more sustainable, circular packaging solutions that reduce environmental impact while ensuring product protection.

The company says this “breakthrough” packaging design offers a high oxygen barrier, excellent optics and enhanced puncture resistance while maintaining optimized formability for hot fill and aseptic applications. The package comprises a thermoformed bottom web and machine direction oriented (MDO) PE lid film, both engineered with ExxonMobil’s premium resins such as Exceed XP, Enable and Exact plastomers, along with Eval’s EVOH resins for barrier properties.

The collaboration utilized Alpine barrier lines for the production of these films, delivering a durable and recyclable solution that meets modern packaging requirements for sustainability without sacrificing performance. The packaging is suitable for hot fill and aseptic applications, making it well suited for food and beverage sectors that require high barrier properties. Its design also further enhances the packaging's environmental credentials as it minimizes material usage while still offering superior protection and sealing properties.

The combination of ExxonMobil’s performance PE and Eval EVOH resins deliver outstanding package integrity, with puncture values after forming comparable to that of nylon containing thermoformed film. In addition, thanks to the latest generation of resins such as Exceed XP, corner thickness after forming is maintained.

Package functionality such as oxygen barrier and optics are comparable to nylon containing thermoformed films. Both the thermoformed bottom as well as the laminated lid were specially designed to provide a broad forming and hermetic sealing window. The result is a film with excellent machinability on the Multivac R245 forming and filling machine. Under optimized thermoforming trial conditions on the R245 Multivac line, maximum line speed (>11 cycles/minute) was achieved with this new design.