For Jacques Human, MD of Kamboo and Kampak, the gap between those two objectives is where much of the industry’s innovation is happening.
Sustainability and recyclability are driving material development, from downgauging and increased recycled content to mono-material structures such as MDO-PE, CPP and BOPE. But the transition is not as simple as replacing one film with another.
MDO-PE with a thin EVOH layer, for example, can deliver an effective environmental barrier while retaining its mono-material status if the EVOH content remains sufficiently low.
Similarly, metallised BOPP combined with heat-sealable BOPP and CPP is emerging as an alternative to METPET/LDPE, maintaining barrier performance while enabling a more readily recyclable mono-material structure.
The technologies are promising, says Jacques, but they are not yet universally ready to replace conventional structures. ‘Cost and ease of conversion are not yet comparable across all these materials,’ he says. A sustainable structure still has to run efficiently, print well, survive converting and deliver the shelf appeal required by brand owners.
For Jacques, one of the industry’s biggest challenges is bridging the gap between recyclability and finished-pack performance. Mono-materials have made significant progress, but barrier layers, printing and finishing can still complicate the equation. ‘Traditional PET-based laminates or foil-backed structures still deliver higher print and finishing quality than most mono-material films today,’ he says.
The aim is to achieve the same print quality, gloss and visual impact on MDO-PE, CPP or BOPE without introducing traditional multi-material structures that undermine recyclability.
Equipment development is also important. Kamboo’s role as a machinery distributor and agent places it between evolving materials and the converting technology required to process them.
Automation is one of the common threads. Jacques points to web tension control as a practical example. While CI presses manage material movement, mid- and narrow-web inline presses require highly automated tension control across multiple stations to maintain consistency.
Efficiency is a key driver of equipment selection. Jacques says the growth of the 550mm-800mm mid-web segment reflects converters matching press width and configuration to individual run lengths, rather than forcing every job onto the same asset.
Kamboo’s work with Weigang’s ZJR 650 and Comexi’s F4 Origin in the mid-web market reflects this trend.
For Kamboo, equipment has to keep pace with material development. XL Plastics’ fully servo-driven pouch machines, for example, can process mono-material and recyclable films while reducing waste and improving production efficiency. Comexi’s hybrid solvent- and water-based press configurations similarly give converters flexibility as substrate and ink requirements evolve.
However, Jacques is realistic about the trade-offs. ‘Although we continue to make progress, we are not yet at a point where performance and sustainability can always be achieved simultaneously,’ he says.
Ed’s note: XL Plastics, Comexi and Weigang are represented and distributed in South Africa by Kamboo.
