ExxonMobil has collaborated with Kuraray, GAP s.r.l. and G. Mondini to develop an ionomer-free plastic film for vacuum packaging applications, offering a lower-cost alternative to conventional ionomer-based structures while maintaining the mechanical performance required for demanding food packaging applications.
Ionomers are widely used in vacuum packaging because of their ability to withstand puncture, tearing and sealing stresses created during the vacuum packaging process. However, ongoing supply constraints and material costs have encouraged packaging manufacturers to seek alternative solutions.
The newly developed structure replaces ionomers with a multilayer polyethylene-based construction. It combines ExxonMobil’s Exceed Flow+ m0516 and Exceed Tough+ m0512 performance polyethylene grades with Kuraray’s ethylene vinyl alcohol (EVOH) for oxygen barrier performance and ExxonMobil’s ethylene-vinyl acetate (EVA) resin to improve stress-crack resistance and low-temperature toughness.
Italian film producer GAP manufactured the multilayer films, while packaging machinery specialist G. Mondini validated the material on its vacuum packaging equipment.
According to an ExxonMobil case study, the ionomer-free film delivers comparable performance to traditional ionomer-based packaging in key areas including toughness, seal integrity, tear resistance and optical clarity, while reducing raw material costs by eliminating the need for ionomers.
The development illustrates how material suppliers, film manufacturers and equipment producers are increasingly working together to address both cost pressures and supply chain challenges in food packaging without compromising package performance.
