Revista de Ciencias Tecnológicas (RECIT). Universidad Autónoma de Baja California ISSN 2594-1925

Volumen 7 (1): e253. Enero-Marzo, 2024. https://doi.org/10.37636/recit.v7n1e253

1 ISSN: 2594-1925

product designers. Therefore, developing or redesigning plastic products in the flexible packaging industry is imperative to ensure

their recyclability at the end of their life cycle. It is necessary to ensure that the mechanical and barrier properties of the ecological

plastic packaging remain intact for specific uses. The current study aims to redesign flexible packaging, focusing on providing the

mechanical and barrier properties of the packaging suitable for food industry applications, thus offering a solution through new

design proposals that allow the development of sustainable and flexible packaging, emphasizing material reduction and recyclability.

This study assessed and compared the mechanical properties of the proposed packaging with those of existing products. The results

demonstrated the feasibility of reducing plastic film thickness or eliminating layers in a tri-laminated structure and transitioning to

a bi-laminated structure. This adjustment did not compromise the mechanical and barrier properties; the oxygen barrier remained

at 35.39 cc/m2*day, and the humidity stood at 0.57 mg/m2*day. This investigation led to a 26.48% reduction in the raw material

consumption of laminated coils and 12.68% in Doypack type packaging used in food applications. Consequently, the decreased

preocupaciones sociales y han alertado a los diseñadores de productos plásticos. Por lo tanto, desarrollar o rediseñar productos

plásticos en la industria del embalaje flexible es imperativo para garantizar su reciclabilidad al final de su ciclo de vida. Es necesario

específicos. El presente estudio tiene como objetivo rediseñar los envases flexibles, enfocándose en proporcionar las propiedades

mecánicas y de barrera del envase adecuadas para aplicaciones de la industria alimentaria, ofreciendo así una solución a través

de nuevas propuestas de diseño que permitan el desarrollo de envases sostenibles y flexibles, enfatizando en la reducción de

materiales y la reciclabilidad. Este estudio evaluó y comparó las propiedades mecánicas del embalaje propuesto con las de los

productos existentes. Los resultados demostraron la viabilidad de reducir el espesor de la película plástica o eliminar capas en una

estructura trilaminada y realizar la transición a una estructura bilaminada. Este ajuste no comprometió las propiedades mecánicas

y de barrera; la barrera de oxígeno se mantuvo en 35.39 cc/m2*día y la humedad se situó en 0.57 mg/m2*día. Esta investigación

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1. Introduction

The daily use of plastic has increased in recent

years because of its multiple characteristics, such

as long life, cost-effectiveness, versatility, and

lightweight nature [1]. It is used in different

environmental problems [3]. According to

research, the production of plastics has risen

exponentially from 2.3 million tons in 1950 to

448 million tons in 2015 [4]. Data on solid waste

management indicate that a staggering 8 million

tons of plastic annually enter the ocean and

pollute rivers [5]. Failure to address this

environmental issue could lead to an alarming

projection: by 2050, the expected quantity of

plastic in the sea will surpass the fish population

plastic on the day-to-day lives of humanity has

been of such magnitude that today, it is difficult

to find products that do not contain some polymer

in their structure or packaging [9]. Several factors

have contributed to the global environmental

problem related to solid waste management.

Therefore, addressing a few issues can help

improve the preparedness and overall

effectiveness of waste management efforts[10].

Unfortunately, however, these problems lead to a

and preventing them from being discarded in

nature [11]. Reintegrating waste into the

productive reuse system minimizes waste

generation and achieves a closed life cycle. The

circular economy offers a solution to promote

sustainable development, expecting to

crucial because it seeks to reintegrate the plastic

resource into the product’s productive system.

Otherwise, all the plastics or packaging

generated with synthetic polymers will end up in

the trash, wasting a resource that could become

the same again or some other product [13].

Consequently, the redesign of products focused

on an environmental and sustainable

development concept, as well as preserving the

main properties that packaging needs, is of the

meaning plastic waste grows yearly. Polymers

are known for their high barrier properties [15].

However, while synthetic polymers exhibit gas,

chemical, biological, or microbial resistance, the

same properties can also make them extremely

difficult to degrade at the final disposal stage of

the product life cycle [16]. Thus, the durability of

synthetic polymers is a double-edged sword.

On the one hand, these materials are solid and

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consider the end-of-life stage of their products

and ensure that the industry can easily recycle

them. This eco-design concept integrates

environmental considerations into the initial

design phase. This approach can lead to better

waste minimization plans and a more sustainable

appearance) and the consumer's willingness to

buy these products [17]. A study revealed that

consumers are willing to pay more for

sustainable packaging to reduce solid waste and

for recycled and recyclable products, indicating a

preference for environmentally friendly options.

Therefore, bioplastic materials will replace fossil

petroleum-based materials in the coming

decades.

the dominant mechanism of decomposition of the

enzymatic action of microorganisms and the

resulting products can be obtained and measured

in a determined period. Biopolymers can solve

the problems posed by plastics because they

degrade quickly in the environment and mimic

the properties of conventional polymers [19].

The need to replace petroleum-derived plastics

with polymers of natural origin is logical because

renewable resources must be biodegradable and

compostable to act as fertilizers and soil

conditioners [20].

Plastic degradation involves irreversible physical

changes, including discoloration, loss of shine,

photodegradation of plastic materials [22],

thermal degradation of polymers [23], chemical

degradation of polymers [24], compostable

polymers [25], and recycling in plastics [26, 27]

Packaging is a critical food manufacturing and

distribution operation [28]. Its main functions are

protection (protection against physical, chemical,

and biological changes), containment (facilitates

transportation and distribution throughout the

of food packaging; thus, several strategies have

been implemented to eliminate unnecessary

packaging. Food packaging materials are mainly

glass, metal, paper, and plastic [30]. Plastics are

classified as thermosets and thermoplastics, with

the latter being the primary packaging material in

the food industry [31]. At a global level, various

modifications have been proposed in the safety

regulations for this type of packaging, which

focus on being eco-friendly, seeking the

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Flexible packaging is an emerging packaging

technique that exploits the particular

functionalities of several polymers to develop

improved packaging in terms of protection and

durability. A monolayer of polymer is unlikely to

cover all food packaging needs, including

various materials, including different polymers,

to produce laminations that are not recyclable.

Therefore, the engineering function for a flexible

packaging operation must design products and

processes that deal with both challenges of "fit-

for-use" and "fit-to-make" [34].

Consequently, it is essential to consider

redesigning the packaging to incorporate

recyclable materials and take some actions to

this helps reduce plastic waste and promotes an

Flexible packaging designers reduce raw

material consumption and optimize resource

usage in mass production. They strived to

maintain the essential properties that ensure the

product's quality, extend its useful life, and

facilitate transport and distribution. A necessary

attribute of flexible packaging is its ability to

PET, low- and high-density polyethylene (LDPE

and HDPE, respectively), polypropylene (PP),

polyvinyl chloride (PVC), and polystyrene (PS)

are the most popular packaging materials. Using

biopolymer materials is a sustainable alternative

to synthetic polymers, mainly because of their

The flexible packaging industry faces a

significant challenge in redesigning all

packaging to be optimally recycled or

reintegrated into the earth in an environmentally

friendly manner. Packaging films made of

synthetic polymers are nonbiodegradable and

Flexible packaging today has an opportunity for

improvement; when thinking about a design that

considers circular economy criteria, the

inorganic coatings [41]. Designing and

manufacturing flexible packaging with diverse

polymers creates a barrier to recycling.

Recycling such packaging becomes complex and

costly because of the bonding of plastic films

through adhesives during the lamination process.

Moreover, separating these layers poses a

significant challenge. Consequently, it is crucial

to develop flexible packaging solutions that

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recyclable. Here, it includes a methodology that

compares the mechanical and barrier properties

of the current multi-polymeric design with a

thinner, mono-material structure. In designing

biodegradable flexible packaging, it is essential

to characterize the properties of the packaging to

material flexible packaging with sustainability

criteria. These criteria include integrating

materials of the same polymeric origin, reducing

lamination layers, and decreasing the thickness

and weight of the packaging.

The research also emphasizes ensuring that the

packaging, at the end of its life cycle, can be

reintegrated into the value chain as a raw material

using mechanical recycling without

Furthermore, reducing the thickness and base

weight of the packaging leads to savings in raw

material consumption and decreased production

costs. Therefore, it is crucial to analyze the

mechanical, physical, and barrier properties of

multi-material and multi-layer packaging,

comparing them with the proposed designs

incorporating sustainability criteria. This

analysis is necessary to determine if it is possible

to maintain optimal levels of packaging

Currently, a significant challenge lies in finding

specific applications in packaging within the

food sector that allow for the implementation of

designs based on sustainability criteria. It is

essential to consider the shelf life requirements

for the product to be packaged during the design

2.- Methodology

coil and Doypack) was carried out. A

comparative study of the commercial structures

was carried out, as well as the structure of the

ecological proposal of the following mechanical

properties: a) thickness, b) weight, c) lamination

force, d) sealing strength, e) resistance tensile

strength, f) percentage of elongation, g)

coefficient of friction, h) oxygen and i) water

vapor permeability of laminated coil and

Doypack plastic containers. Finally, the

2.1.- Proposals for the redesign of flexible

Numerous sustainable design projects and

initiatives have emerged with the intention of

reducing the environmental impact caused by the

flexible packaging industry. These endeavors

focus on implementing design methodologies

within industrial settings to foster the

development of environmentally friendly

products. This framework assesses the physical

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2.1.2.- Reduction of lamination layers in

trilaminate structure for flexible packaging in

the food sector in laminated coil

2.1.2.1. Processes to obtain flexible laminated

to highlight that there are processes preceding the

production of the laminated coil, such as the

plastic film extrusion processes, but for this case,

they are not taken into account since the coil

production process already includes plastic films

extruded A) obtaining a reel with an image

referring to the product to be packaged, this

consisted of printing on a plastic film by

rotogravure, the color selection for the generation

of the image (CMYK) 10 nitrocellulose-based

with an acrylic-based polymeric adhesive, which

was diluted with ethyl acetate with its catalyst for

lamination at a speed of 250 m/min. It was left to

stand for 8 hours. C) Cutting process: this was

done through an unwinder and blades; the coil's

width is 395 mm, and the outer diameter is 350

mm.

Doypack packaging: Like the laminated coil, the

folds were generated through a laminated coil,

sealing the sides and the bottom with hot jaws.

The sealing temperature for creating the package

was 180-220 °C, and the jaw contact time was 0.5

s.

A proposal to reduce the environmental impact of

plastics in the flexible packaging industry is to

reduce raw material consumption and eco-

design. As shown in Table 1, coil packaging for

requirements to ensure the packaging is suitable

for the intended application.

Natural BOPP (bi-

oriented polypropylene)

20

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The methodology proposed to work on

improving weight reduction through the

application of lamination layers and a trilaminate

structure in flexible coil packaging. Therefore,

the proposal suggests using a bilaminate and

trilaminate structure in coil food packaging, as

shown in Table 2.

Table 2. Bilaminate structure proposed in flexible packaging of the food sector in coil

Proposal structure

polypropylene)

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Destructive drop test criterion: In the

experimental setup, the sealing of the product

procedure is conducted using bespoke sealing

equipment. This custom apparatus features

precision-engineered steel jaws carefully

designed to ensure optimal performance and

Furthermore, pneumatic pressure equipment was

incorporated into the experimental framework,

providing a controlled and consistent application

of pressure during the sealing procedure. This

equipment has pressure regulation mechanisms

to guarantee uniformity and repeatability across

multiple trials. Including a seal time controller

further enhances the experimental control,

allowing for precise adjustment and monitoring

of the duration for which the sealing process is

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chamber. The chamber, characterized by its

complete hermetic sealing, features dimensions

of 35x25x35 cm, ensuring a controlled and

standardized environment for the experimental

procedures. Using acrylic material not only

enhances transparency, allowing for real-time

Integral to the functioning of this apparatus is a

robust 1-horsepower (1hp) motor engineered to

generate and maintain a vacuum within the

equipment. The applied vacuum ranges from 25

to 40 cmHg, a carefully selected parameter that

aligns with the specific requirements of the

Revista de Ciencias Tecnológicas (RECIT): Volumen 7 (1): e253.

lamination layer, meticulous destructive tests

affirm that the ecological packaging satisfies the

stipulated requirements for the specific product.

This assertion is supported by the outcomes of

drop resistance, resistance to air pressure, and

vacuum tightness tests, where the doypack

augmentation is attributed to polyethylene in

both laminate layers, conferring elevated

resistance to the packaging while on the shelf.

The comprehensive analysis of these findings

underscores the viability and efficacy of the

proposed ecological packaging regarding

material reduction and cost efficiency and in

meeting and surpassing the mechanical and

functional requisites for the intended product.

structure is a viable option for recyclable

packaging. This approach reduces raw material

consumption by eliminating a lamination layer,

thus contributing to a circular economy through

recycling and reintegrating packaging into the

value chain. This modification ensures that the

packaging maintains sufficient mechanical

strength for long-term durability.

4. Conclusions

also necessary, and above all, the packaging must

provide the product with a long shelf life without

compromising its contents. It is essential to use

the properties of different polymers while

ensuring that the packaging is attractive to

consumers. If the packaging is visually

recycled, thus enabling the product to be used as

a raw material. Hence, it is crucial to ensure that

the physical properties of the packaging are not

affected by using fewer raw materials, reducing

thicknesses, reducing lamination layers, and

incorporating biodegradable materials.

Furthermore, if any of these changes affect the

physical properties, it is crucial to determine to

what extent such alterations are permissible.

Furthermore, polymeric materials can be crucial

in reducing the environmental impact while

achieving these goals.

Today, the packaging industry and engineering

and design areas play an essential role in

developing packaging solutions that prioritize

sustainability. This experiment seeks to renew all

existing packages while creating new ones

incorporating sustainability principles.

Revista de Ciencias Tecnológicas (RECIT): Volumen 7 (1): e253.

properties are not affected and, in some cases,

can be improved. This benefits the reduction of

the environmental impact due to the consumption

of raw materials. In addition, it generates an

economic reduction in sales prices, increasing the

product's profit margin.

once its life cycle has ended, unlike laminated

coils or Doypacks that are processed using

monomaterials, in addition to having a reduction

in raw materials, are products that can be

mechanically recycled as they have polymeric

compatibility.

This study shows that the mechanical properties

of single-material packaging are completely

functional compared with those of multi-material

As can be seen, the improvement proposals that

include materials that can be recycled more

quickly due to polymeric compatibility can be

considered sustainable since non-renewable

resources, which in this case is oil, could be used.

Under this premise, raw materials are

reintegrated into the value chain of the finished

product. Raw materials can be reused several

times through mechanical recycling.

system through recycling, and generating a

benefit to the environment can result in economic

savings in the cost of the finished product.

Recycling currently presents challenges because

a product is designed to be recycled. However,

pollutant that affects recycling.

The main goal is to eliminate laminations and

generate single-layer flexible packaging.

However, the ink with which an image is placed

on the product's packaging will continue to exist.

Nowadays, the technology of inks that can be

removed using a particular chemical is emerging.

It is in the initiation stage but is intended to have

flexible packaging of a single polymer that can