ExxonMobil Develops Sustainable PE Films With PCR Content

ExxonMobil Signature Polymers has developed two innovative monomaterial polyethylene (PE) film solutions that incorporate up to 35% post-consumer recycled (PCR) content.

The breakthrough addresses a primary challenge in the consumer goods sector: integrating recycled plastics into high-speed, heavy-duty applications without inducing material tearing, degradation, or processing slowdowns. Specifically engineered for hygiene compression packaging (such as diapers and sanitary products), the new films enable downgauging (thickness reduction) and easy recyclability while matching the strict performance baselines of 100% virgin plastics.

A Streamlined Three-Grade Material Backbone

Traditionally, blending PCR content into thin films compromises structural integrity, causing elongation or sealing failures. To solve this, ExxonMobil’s development team worked directly across the packaging supply chain to build an optimized formulation relying on just three distinct polyethylene grades:

• Exceed™ Tough+ m 0518 mPE: A metallocene polyethylene that serves as the formulation’s structural backbone, providing extreme puncture resistance and tear toughness.

• ExxonMobil™ HD 6207FL: A high-density polymer that delivers the high stiffness and creep resistance necessary to maintain dimensional package shape under compression.

• ExxonMobil™ LD 07523: A low-density polymer introduced in minor quantities to fine-tune film optical clarity, surface gloss, and manufacturing processability.

Industrial Validation and Machinery Compatibility

To ensure the new PCR-formulated films could be seamlessly adopted by global manufacturers without sacrificing factory throughput, ExxonMobil validated the films on commercial-grade processing lines:

• Conversion: The monomaterial films were fed through Hudson-Sharp’s Apollo wicket machine. Even at ultra-thin gauges, the film demonstrated high cutting precision, easy side punching, and strong thermal sealability, maintaining high manufacturing output.

• Packaging and Bagging: The films were tested on high-speed Optima forming and sealing machinery. The formulations provided enough stiffness to prevent stretch deformation during mechanical handling, alongside a precise coefficient of friction for automated robotic grippers.

Crucially, commercial bagging operations achieved top processing speeds without requiring adjustments to existing machine settings, giving converters a plug-and-play pathway to lower their environmental footprint.