WorldStar Winner: 30% PCR Mono-PE Flexible Packaging for Laundry Powder Detergents

WINNERS 2025

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30% PCR Mono-PE Flexible Packaging for Laundry Powder Detergents

Company:

Isabella Carloni - Henkel AG & Co. KGaA

www.henkel.com/

Country: Germany

Category: Household

Our submission should be awarded because it represents a significant advancement in sustainable packaging by integrating 30% post-consumer recycled (PCR) material into a mono-PE laminate film. The development focused on maintaining the film's processability on industrial Vertical Form Fill Seal (VFFS) lines, ensuring that it can be seamlessly integrated into existing manufacturing processes without compromising efficiency or quality. The primary advantages include no increase in the packaging structure's weight compared to conventional virgin counterparts and no changes in visual perception regarding print quality and film surface. This solution is applicable in the packaging of laundry powder, with bags ranging from 1kg to 12kg in three different film thicknesses: 100μm, 110μm, and 160μm. It is particularly relevant for markets prioritizing sustainability without sacrificing performance.

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This project was executed through a strong collaboration between Borealis, the PCR supplier; Korozo, the film converter; and Henkel, the brand owner. Together, we enhanced our processes and developed a successful packaging solution that meets the high standards required by premium laundry detergent brands. This initiative impacts seven renowned brands across twelve countries in Europe, with a projected distribution of 18.5 million consumer units in 2024—equating to 450 tons of plastic, including 135 tons of Post-Consumer Recycled (PCR) material.
The incorporation of PCR material in primary packaging for premium products is still rare in today’s market, presenting a significant opportunity to drive demand within the recycling industry, particularly for flexible packaging. This effort not only promotes the circularity of materials but also improves the quality of recyclates, paving the way for more sustainable packaging solutions.

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