Monomaterial Packaging: a strategic decision for PPWR compliance

How to develop packaging solutions built to meet the challenges of PPWR? Gino Tansini, Product Development Manager at Gualapack, explores the advantages of monomaterial packaging in driving greater sustainability, without compromising product protection.

“After working on many different packaging projects, I've learned that the discussion rarely startswith the material itself. The real question is how to achieve the right balance between recyclability, product protection and manufacturing efficiency. Every application has its own constraints, and that's what makes product development interesting.”
Gino Tansini
Product Development Manager | Gualapack

From my perspective, 2030 is much closer than it seems. Packaging development projects take time, and by the time a new solution has been tested, validated and qualified for production, several months or even years may already have passed.

The European Packaging and Packaging Waste Regulation (PPWR) is setting a clear direction: packaging placed on the EU market will increasingly need to be designed for recyclability. For many brand owners, this means that packaging decisions being made today will determine whether products are ready for tomorrow's regulatory landscape.

The challenge is that redesigning packaging is rarely quick. New materials must be tested, shelf life validated, filling lines qualified and production scaled. For companies managing dozens—or hundreds—of product references, the transition can take years rather than months.

 That's why I'm seeing more and more customers beginning the transition to monomaterial packaging today rather than waiting for regulatory deadlines.
In practice, however, moving to a monomaterial structure is never as simple as replacing one film with another.

A baby food pouch, a dairy product and a home care refill all require different levels of protection. The objective is not to maximise the barrier at all costs, nor to minimise it in pursuit of recyclability. The objective is to find the right barrier: one that protects the product throughout its shelf life while supporting a packaging design compatible with future recycling streams.

Some applications require only moderate barrier properties, while others demand high oxygen protection or resistance to thermal treatments. Retort applications, for example, present some of the most demanding technical challenges: Finding that balance is where experience matters.

Long before PPWR became part of everyday conversations, we recognised this shift and started developing practical monomaterial solutions. In 2020, Gualapack introduced Pouch 5, the first monomaterial spouted pouch, opening the way for recyclable pouch solutions without compromising the convenience consumers expect. Since then, projects across food, beverage, dairy, pet food and personal care have expanded that experience into practical know-how, providing premade spouted and unspouted pouches, as well as laminates for FFS technology.

One thing I've learned over the years is that there is no universal monomaterial solution. Every application has its own technical requirements, and every transition begins with understanding the product before selecting the packaging. Recycling infrastructure of the destination market, material choice, barrier performance, spouts, caps, converting and filling technology all need to work together as a single system.

When I discuss packaging strategies with customers, I always encourage them to ask a different question. Rather than 'Which monomaterial should we choose?', the real question is 'Which monomaterial solution is right for our product and location?'

Whether you are taking the first steps towards recyclable flexible packaging or planning the transition of an existing product portfolio, Gualapack can help you identify the solution that combines product protection, production efficiency and compliance with tomorrow's packaging requirements.

The roadmap to 2030 has already begun. If monomaterial packaging is part of your future, now is the right time to start the conversation. Contact Gualapack to discuss the solution that best fits your products and your sustainability goals.