Client Background
Type: Major frozen vegetable processor in East China, exporting to EU & North America
Products: Frozen broccoli, spinach, sweet corn, mixed vegetables
Annual export volume: ~50,000 tons
Previous packaging: PET/PE laminated bags (transparent, 80μm)
Challenge
Poor freshness: OTR of PET/PE film was 5–8 cc/m²·day; after 45-day ocean transit, vegetables suffered freezer burn (dehydration, whitening, off-taste), return rate hit 8%.
Regulatory pressure: EU PPWR required higher recyclability, with 100% recyclable packaging by 2030. PET/PE laminates are non-recyclable, risking market access.
Rising costs: Plastic taxes and EPR fees added extra cost for non-recyclable packaging.
Solution
After testing four structures, we selected:
All-PE mono-material 5-layer co-extruded film: Outer (mechanical strength) + barrier (PE-specific oxygen-blocking formula) + tie + functional (easy-tear) + sealant. No EVOH/PA used – 100% PE recyclable.
Thickness reduction: From 80μm to 55μm, reducing material usage while maintaining puncture and seal strength.
Printing adaptability: Surface treatment reached 38 dyne/cm for excellent ink adhesion on high-speed printers.
Results (Quantified)
OTR reduced to 1.2 cc/m²·day; WVTR to 0.9 g/m²·day; shelf life extended from 6 to 12 months
Freezer-burn return rate dropped from 8% to 2.8% (65% reduction)
Packaging is 100% recyclable in PE streams; client earned EU-recognized recycling credits
Thinner film yields 18% more packaging area per ton, reducing overall cost by 6%
Client Testimonial “They solved our freshness issue and gave us confidence in facing EU regulations. Now our packaging is both eco-friendly and attractive – our customers love it.” – Technical Director
