Dow and Walki Develop Recyclable Monomaterial MDO-PE Matte Pouch

Photo Credit: Walki

Dow and Walki have jointly developed a monomaterial polyethylene (PE) pouch using machine direction orientation (MDO) technology, designed for frozen and dry food packaging applications and targeting improved recyclability alongside premium shelf appearance.

The prototype pouch combines Walki’s film design, printing, lamination, and finishing capabilities with Dow’s low-temperature sealing materials. The companies say the structure replaces conventional multilayer laminates based on materials such as oriented polyester (PET), enabling a fully PE-based solution intended for mechanical recycling streams.

The development focuses on applying MDO processing to polyethylene films to enhance stiffness, dimensional stability, and barrier performance while maintaining a mono-material structure. The process involves stretching PE film in the machine direction, improving mechanical properties that are typically required for high-performance flexible packaging.

Walki noted that achieving a matte surface finish in MDO-PE structures has traditionally been difficult. Matte appearance is increasingly used in premium food packaging segments, particularly in frozen and prepared meals, where brands are repositioning products as higher-value offerings rather than convenience items.

“There has been a need for a solution that delivers the functional performance of MDO-PE but with a premium matte appearance,” said Juan Angel Ruiz Salazar, R&D Manager at Walki Plasbel. “We designed the pouch and performed the printing, lamination, and finishing process.”

He added that MDO-PE presents processing constraints compared with materials such as PET, particularly in terms of thermal resistance. Unlike PET-based laminates, which can withstand higher sealing temperatures, MDO-PE requires lower heat input to avoid deformation during conversion and sealing.

To address this limitation, the pouch uses a PE sealant layer designed to operate at reduced sealing temperatures. Dow said its Affinity polyolefin plastomers were selected for their ability to activate and seal at low temperatures, enabling compatibility with heat-sensitive MDO layers.

According to Dow, the material also supports improved machinability, reduced film blocking, and stable performance on high-speed packaging lines. The companies say these properties can contribute to higher extrusion efficiency and lower production costs while maintaining recyclability.

“This enables a higher extrusion output, equipment efficiency, and overall cost savings when producing recyclable packaging,” said Ksenija Maksimovic, Senior TS&D Specialist at Dow Packaging & Specialty Plastics EMEA. The prototype was presented at Interpack 2026 in May, where it drew significant industry interest, she added.

The pouch was demonstrated using frozen gyoza as a test application, but Dow and Walki said the structure is suitable for a broader range of food packaging uses, including cereals and modified atmosphere packaging formats for fresh foods.

The development aligns with broader regulatory pressure in Europe under the Packaging and Packaging Waste Regulation (PPWR), which is pushing converters and brand owners toward design-for-recyclability requirements and increased adoption of mono-material structures in flexible packaging.

Walki emphasized that recyclable packaging plays a functional role in reducing food waste by extending shelf life and maintaining product quality. The company said packaging design should balance material circularity with performance requirements in order to reduce overall lifecycle emissions.

Jonas Skuthälla, Head of Sales for Flexible Packaging at Walki, said the industry should focus less on material competition and more on keeping materials in circulation. “When designed for circularity, plastic packaging plays a critical role in extending shelf life and preserving food quality,” he said. “Rather than asking which material is ‘better,’ the priority is to keep materials in use and within the loop.”

The collaboration reflects continued investment in mono-material flexible packaging solutions as converters and resin producers respond to tightening European recyclability criteria and rising demand for high-performance recyclable packaging formats.

Source: Walki

SUNSHINE Spotlight: Dow and Walki’s MDO-PE matte pouch demonstrates how mono-material polyethylene structures are being engineered to replace multilayer laminates in frozen food packaging while maintaining performance and improving recyclability.