Extrusion International 3-2026

21 Extrusion International 3/2026 Reduction in Material Usage for Plastic Packaging Plastics are an integral part of the packaging industry: they pro- vide reliable protection for prod- ucts, often have a lower carbon footprint than alternative mate- rials, and can be processed effi- ciently. At the same time, pressure is mounting on manufacturers to conserve resources and further reduce raw material use – with- out compromising on stability, functionality or recyclability. With the introduction of the EUPPWR, from 2030 onwards only packag- ing that is fully recyclable may be placed on the market; in addition, there are ambitious targets for the use of recycled materials. Promix Solutions offers an economically and environmentally sound solu- tion to these challenges: Microcell technology. It typically reduces packaging weight by around 20%, fully preserves mechanical proper- ties and, at the same time, enables true recyclability. Lighter packaging – same performance – signi cant cost savings Microcell technology involves incorporating environmentally neutral gases such as CO2 or N2 into the plastic. This creates a fine- pored, microcellular foam struc- ture. Cell size and cell distribution are crucial: a very fine and homo- geneous structure ensures that cups or trays achieve the same stability as conventionally manu- factured packaging even after thermoforming – despite a signifi- cantly reduced density. A typical extrusion line for packag- ing lms with a throughput of 800 kg/h saves up to 3.8 tonnes of plastic per day using Microcell technology. This equates to around €3,800 per day or over €80,000 per month. Ex- trapolated over a year, this results in a reduction of around 1,000 tonnes of plastic per line. The lower lm weight for the same lm thickness not only re - duces energy consumption during thermoforming but also reduces transport weight – which leads to an overall improvement in the car- bon footprint. The technology is suitable for virtually all polymers and can be seamlessly integrated into both existing and new produc- tion lines. Environmentally friendly and fully recyclable As Microcell uses environmentally neutral blowing agents and con- tains no environmentally harmful additives, the packaging remains fully recyclable. Even production waste, such as that generated dur- ing thermoforming, can be easily recycled, as the additive does not accumulate in the material as is the case with chemical blowing agents. Microcell technology is suitable for a wide range of packaging ap- plications produced using extrusion and thermoforming processes: food packaging such as pots or trays, boxes and technical packaging, as well as form- ll-seal (FFS) applica - tions. Case study: The ‘lightweight’ yoghurt pot In the case of yoghurt pots, which are often produced using the FFS process, Microcell enables a 20 to 25% reduction in material usage without compromising on shelf life or product protection. Whilst polystyrene is traditionally used, polypropylene and polyester are becoming increasingly important. Case study: PP clamshell tray In a 3-layer PP clamshell tray, the Microcell core layer forms the heart of the design. Sandwiched between two solid outer layers, it signi cantly improves insulation and withstands temperatures of up to 100°C. The foam structure reduces the material density considerably – in this exam- ple by 40%. Microcell PP is a sustainable alter- native to polystyrene or paper-coat- ed solutions. As a mono-material, it fully complies with the require- ments of the European Packaging and Packaging Waste Regulation Left: Yoghurt pots manufactured using Microcell technology save 20–25% plastic. Right: Microcell structure in the core layer of an FFS lm (Images: Promix Solutions AG)