Interpack 2026 Insights: Optimizing Co-Extruded Film Structures for Sustainable Packaging

At Interpack 2026, sustainable packaging was one of the most prominent topics. From bio-based materials to single-material recyclable designs, and from antimicrobial functionality to extended shelf life, the packaging industry is experiencing a major transformation. For food packaging film manufacturers, this represents both a challenge and a strategic opportunity.

Multi-layer co-extrusion technology, with its flexibility in combining different materials, has become a key method to balance performance and sustainability. The question for manufacturers is: how can co-extruded film structures be optimized to protect products effectively while meeting global trends for carbon reduction, plastic minimization, and recyclability?

1. Transitioning from Multi-Material Composites to Single-Material Co-Extrusion

The concept of a circular economy was central throughout Interpack 2026. Experts highlighted that recyclable packaging is no longer optional—it is a market entry requirement in the EU and other regions.

For co extruded films, the primary improvement is moving from traditional multi-material composites to single-material structures such as all-PE or all-PP films.

Conventional high-barrier packaging often uses PET/AL/PE or PA/EVOH/PE composites. These multi-material layers, especially aluminum foils, are difficult to separate during recycling, leading most of these packages to be incinerated or landfilled.

Multi-layer co-extrusion allows manufacturers to combine high-barrier layers (e.g., EVOH) with PE or PP using adhesive resins, creating fully polyolefin structures. According to CEFLEX guidelines, EVOH content below 5% still allows the structure to enter the existing PE recycling stream. Optimizing EVOH thickness (e.g., 5–8 μm) and its position in the middle layer ensures excellent oxygen barrier performance while complying with recyclable packaging standards.

Additionally, all-PE co extruded film can now achieve high stiffness and heat-seal performance, suitable for snack bags, courier bags, and other non-high-barrier applications.

2. Incorporating Bio-Based Materials into Co-Extrusion

Another highlight of Interpack 2026 was the growing application of bio-based materials. The Fraunhofer IVV’s MATE4MEAT project demonstrated next-generation bio-based antimicrobial packaging, replacing conventional plastics with plant-derived materials while extending meat shelf life.

For film manufacturers, integrating bio-based polyolefins (such as sugarcane-based PE or corn-based PLA) into co extruded multilayer film requires careful consideration of processing temperature, interlayer adhesion, and barrier performance. For instance, PLA melts at 160–200°C, while PE requires 180–220°C. Using compatibilizers or multi-layer transition layers can overcome these challenges.

Because bio-based materials often have lower barrier properties, manufacturers can increase EVOH layer thickness or apply multi-layer barrier stacking to achieve comparable oxygen and moisture resistance.

3. Thinner, Lighter, and More Efficient: Optimizing Film Structures

Sustainability at Interpack also focused on reducing material use without compromising protection. Using less material directly lowers carbon footprint and aligns with EU packaging waste directives.

Multi-layer co-extrusion offers precision in layer thickness, enabling lighter films without sacrificing performance.

For example, a traditional 7-layer fresh meat film may be 120 μm thick, including a 12 μm EVOH barrier and 20 μm PA reinforcement. Optimizing the layer design—splitting thick layers into thinner multiple layers—can reduce overall thickness to 90 μm while maintaining puncture resistance and oxygen barrier performance. Some research at Interpack even showed 20–30% material savings using AI-assisted structural design, with no impact on shelf life.

Controlling thickness variations to ±5% during production further avoids unnecessary material overuse. For high-volume manufacturers, each 10 μm reduction in film thickness translates into a significant carbon footprint reduction, making lightweighting a critical sustainability measure.

4. Integrating Smart and Active Functions to Extend Shelf Life

Reducing food waste is the most effective sustainability strategy. Interpack 2026 emphasized that packaging should not only be recyclable but also actively preserve food.

Multi-layer co-extruded films can integrate active or intelligent layers:

Adding an antimicrobial layer (e.g., EVA with plant extracts) can inhibit microbial growth on meat surfaces. Fraunhofer IVV data shows these films extend meat shelf life by 30–50%.

In modified atmosphere packaging (MAP), high-barrier layers (EVOH or PVDC) combined with oxygen scavenger layers effectively control the gas composition inside the package.

All functional layers comply with food contact material regulations, ensuring safety and market acceptance.

5. Full Lifecycle Approach: Designing for Recyclability

Sustainable packaging requires a holistic lifecycle perspective—from raw materials, production, and use to end-of-life recycling.

For co-extruded film manufacturers, this means recyclability must be considered at the design stage:

Replace hard-to-recycle aluminum layers with high-barrier polyolefins.

Minimize adhesive thickness when combining multiple materials (e.g., PA + PE) to allow separation in recycling.

Reduce inks and adhesives; use water-based rotogravure inks to improve recyclability.

Our company incorporates recyclable design as a standard service, providing recycling certification guidance and structural optimization solutions tailored to the target market—EU, US, or Southeast Asia.

 Co-Extruded Films as a Key Tool for Functional and Sustainable Packaging

Interpack 2026 confirmed that the future of packaging lies in the integration of functionality and sustainability.

By transitioning to single-material designs, incorporating bio-based materials, optimizing structures to reduce thickness and material use, and integrating smart or active layers, co-extruded film manufacturers can meet environmental regulations while delivering packaging that maintains high performance.

Multi-layer co-extrusion provides the flexibility, efficiency, and innovation needed to lead the shift toward truly sustainable food packaging.