ExxonMobil has developed a new generation of ultra-thin polyethylene packaging films for hygiene products, combining reduced material use with recycled content while maintaining high production efficiency.
The development is the result of a collaboration between ExxonMobil, packaging machinery specialist Optima, and converting equipment supplier Hudson-Sharp. The partners set out to address a key challenge facing hygiene packaging manufacturers: incorporating recycled materials into flexible packaging without compromising processability, sealing performance or packaging quality.
The project resulted in two monomaterial polyethylene film structures based on ExxonMobil’s Exceed™ Tough+ m 0518 polyethylene grade. One film focuses on downgauging to reduce material consumption, while the second incorporates up to 35% post-consumer recycled (PCR) content. Both structures also use combinations of ExxonMobil high-density and low-density polyethylene resins.
According to the company, the films were engineered to deliver the mechanical strength, sealing characteristics and processing performance required for hygiene packaging applications while supporting sustainability objectives.
Film development was carried out at an ExxonMobil facility before conversion trials were conducted using a Hudson-Sharp Apollo slitter-rewinder. The materials were subsequently formed and sealed on Optima packaging equipment.
During testing, the films demonstrated strong sealing performance, efficient side trimming and die-cutting, and compatibility with high-speed packaging operations. The companies reported that pouch production could be carried out without requiring changes to existing end-user machine settings, helping manufacturers integrate the materials into current production environments.
ExxonMobil said the films are designed to support growing demand for more sustainable flexible packaging solutions by reducing material usage and increasing recycled content while maintaining package integrity and shelf appearance.
In addition to their environmental benefits, the films offer printability and optical properties intended to support branding and product presentation requirements for hygiene product manufacturers.
