The Future of Food Packaging Under the EU PPWR

The European packaging industry is entering a new phase of regulatory change. The EU Packaging and Packaging Waste Regulation (PPWR), Regulation (EU) 2025/40, has applied since 12 August 2026, introducing new requirements for packaging design, material composition, recyclability, and waste management.

For food manufacturers, these changes go beyond choosing environmentally friendly packaging materials. They may also affect packaging film suppliers, product protection, sealing performance, production efficiency, and the machinery used on packaging lines.

One important development is the growing interest in recyclable mono-material packaging. Traditional multi-layer packaging structures, which combine different materials to achieve high barrier performance, may face additional design and recyclability challenges.

For manufacturers using Vertical Form Fill Seal (VFFS), Horizontal Form Fill Seal (HFFS), and flow wrapping machines, the transition to new packaging films raises an important question:

Can existing packaging machines handle the next generation of recyclable flexible packaging materials without compromising sealing quality and production efficiency?

This article explains the main PPWR requirements, the development of recyclable packaging films, and the practical considerations food manufacturers should evaluate when adapting their packaging equipment.

1. What Is the EU PPWR and Why Does It Matter?

The Packaging and Packaging Waste Regulation (PPWR) is an EU regulation designed to reduce packaging waste, improve recycling, and promote a more circular packaging economy.

Unlike a directive that requires national transposition, the PPWR establishes a directly applicable framework across EU Member States.

It covers packaging throughout its lifecycle, including manufacturing, composition, use, collection, and recycling.

Key PPWR Implementation Dates

Several requirements are being introduced in stages.

12 February 2025 – Regulation Entered into Force

Regulation (EU) 2025/40 formally entered into force, establishing the new EU framework for packaging and packaging waste.

12 August 2026 – General Application Begins

The PPWR began applying across the EU. One particularly important measure for food manufacturers is the restriction on PFAS in food-contact packaging.

Under Article 5(5), food-contact packaging must not be placed on the EU market if PFAS concentrations reach or exceed the specified limits:

• 25 ppb for any individual PFAS measured through targeted PFAS analysis, excluding polymeric PFAS from quantification.

• 250 ppb for the sum of PFAS measured through targeted analysis, where applicable following precursor degradation, also excluding polymeric PFAS from quantification.

These restrictions are particularly relevant to food-contact materials and packaging suppliers. Manufacturers should obtain appropriate material declarations and test information from their suppliers.

2028 – Harmonised Packaging Labelling

A harmonised EU packaging labelling system is scheduled to apply from 2028 to help consumers identify packaging materials and dispose of them correctly.

2030 – More Extensive Packaging Requirements

By 2030, additional requirements will apply, including:

• All packaging must meet the applicable recyclability requirements.

• Minimum recycled plastic content requirements will apply to relevant plastic packaging categories.

• Restrictions on certain single-use plastic packaging will apply.

• Additional measures will address packaging waste prevention and reuse.

The exact obligations depend on the packaging category and relevant provisions of the regulation.

For food manufacturers, this means packaging decisions made today should consider not only current production requirements but also future material compliance.

2. The Shift Toward Recyclable Mono-Material Packaging

One of the major developments in flexible packaging is the increasing adoption of mono-material structures.

Traditional flexible packaging often uses multiple material layers to achieve the required combination of mechanical strength, moisture resistance, oxygen barrier, printability, and heat sealing.

For example, a conventional laminate may combine:

• PET for mechanical strength and printability.

• Aluminum foil or metallized layers for barrier performance.

• PE or CPP as the heat-sealing layer.

These combinations can provide excellent product protection. However, separating different material layers during recycling can be technically challenging.

Mono-material packaging aims to simplify the material structure by using predominantly one polymer family, such as polyethylene (PE) or polypropylene (PP).

Common Mono-Material Packaging Options

Mono-PE Packaging

PE-based structures are commonly considered for flexible packaging applications requiring good flexibility and heat-sealing properties.

They can be developed for products such as frozen foods, snacks, powders, and certain dry food products.

Depending on the structure, barrier requirements may be improved through compatible coatings or other specially designed layers.

Mono-PP Packaging

PP-based flexible packaging can offer useful stiffness, heat resistance, and sealing characteristics.

It is used in applications such as snack packaging, confectionery, and other food products.

The exact film structure must be selected according to the product, packaging process, and intended recycling route.

Does PPWR Require All Packaging to Be Mono-Material?

No.

The PPWR does not simply require every food package to use a single material.

Its objective is to ensure that packaging meets the applicable recyclability criteria. Mono-material structures are one possible way to improve recyclability for certain flexible plastic packaging applications.

Other packaging structures may also qualify if they meet the relevant design-for-recycling requirements.

Therefore, manufacturers should evaluate the complete packaging structure rather than assuming that a mono-material label automatically guarantees compliance.

3. Challenges Facing Traditional Multi-Layer Packaging Films

Traditional composite films have been widely used because different materials can provide complementary performance.

For example, PET/AL/PE structures can provide mechanical strength, strong barrier properties, and a heat-sealable inner layer.

However, packaging manufacturers may need to reconsider these structures as recyclability requirements become more important.

3.1 Recycling Compatibility

Different polymers and materials can behave differently during recycling.

When incompatible materials are combined in one flexible package, the resulting recycled material may have reduced quality or limited applications.

Packaging designers therefore need to consider whether the complete structure is compatible with the intended recycling process.

3.2 Product Protection Requirements

A packaging material must still protect the food inside.

Some products require high oxygen or moisture barriers to prevent oxidation, moisture absorption, flavor loss, or other quality problems.

Replacing a traditional laminate with a simpler material structure should not compromise the required shelf life.

This is particularly important for:

• Coffee and powdered beverages.

• Nuts and dried fruits.

• Snacks and confectionery.

• Frozen foods.

• Products sensitive to oxygen or moisture.

3.3 Heat-Sealing Performance

Different film structures have different heat-sealing characteristics.

Some recyclable flexible films may have narrower or different sealing conditions compared with conventional laminates.

This can affect:

• Sealing temperature.

• Sealing pressure.

• Dwell time.

• Seal strength.

• Production speed.

• Resistance to product contamination in the seal area.

The packaging film must therefore be tested on the actual production machine before manufacturers finalize a material change.

4. How Will New Packaging Films Affect Packaging Machines?

The transition to recyclable packaging materials is not only a material selection issue.

It also affects the performance of the machinery used to form, fill, and seal packages.

Different films may require adjustments to the machine's temperature settings, sealing system, film feeding mechanism, and operating speed.

4.1 VFFS Machines: Adapting to New Flexible Films

Vertical Form Fill Seal machines are widely used for packaging powders, granules, snacks, nuts, and other food products.

A VFFS machine forms a bag from a roll of packaging film, fills the product vertically, and seals the package.

When switching from traditional laminates to recyclable PE- or PP-based structures, manufacturers should evaluate several factors.

Sealing Temperature and Time

Different films have different heat-sealing windows.

The longitudinal and transverse sealing systems may need temperature and dwell-time adjustments to achieve reliable seals.

Film Feeding and Tension Control

Film thickness, stiffness, friction, and elongation characteristics can affect film transportation.

The film pulling mechanism and tension settings may require adjustment to maintain stable bag formation.

Forming Shoulder and Film Tracking

A new film structure may behave differently when passing through the forming shoulder.

Manufacturers should check whether the film runs smoothly, forms the required bag shape, and maintains accurate tracking.

Cutting and Sealing Synchronization

Changes in film behavior may influence bag length accuracy and cutting performance.

The machine should be tested to confirm that sealing and cutting remain properly synchronized.

4.2 HFFS Machines: Handling New Flow Wrapping Materials

Horizontal Form Fill Seal machines are commonly used for biscuits, bread, confectionery, frozen foods, and other individual food products.

They form packages around products while transporting them horizontally.

When using recyclable flexible films, several machine parameters need attention.

Longitudinal and End Sealing

The sealing system must provide sufficient heat and pressure to create consistent seals.

Different film structures may require changes to sealing temperature, pressure, and contact time.

Film Transport and Registration

The film must travel smoothly through the machine while maintaining accurate product positioning and cutting length.

The photoelectric registration system should be tested with the new film's printed color marks and contrast characteristics.

Machine Speed

Some recyclable films may require different sealing conditions or longer dwell times.

As a result, the original production speed may not always be achievable without adjustment.

Actual output should be confirmed through production trials.

4.3 Flow Wrapping Machines: Maintaining Seal Quality and Packaging Appearance

Flow wrapping machines are widely used for individual food products such as bread, biscuits, chocolate bars, and confectionery.

The film wraps around the product and is sealed longitudinally and transversely.

For recyclable films, manufacturers should pay attention to:

• Film friction and smooth feeding.

• Seal temperature and pressure.

• Longitudinal seal overlap.

• End-seal strength.

• Cutting accuracy.

• Package appearance and tightness.

A film that performs well on one flow wrapper may not deliver identical results on another machine because sealing structures, jaw designs, and operating conditions differ.

For this reason, actual machine testing is essential.

5. How Should Food Manufacturers Prepare for the PPWR?

The transition to new packaging materials should be treated as a coordinated project involving packaging suppliers, food manufacturers, and machinery manufacturers.

Here are five practical steps to consider.

Step 1: Review Existing Packaging Structures

Identify the materials currently used for each product.

Review the complete laminate structure, including:

• Outer printing layer.

• Barrier layer.

• Adhesive layers.

• Inner heat-sealing layer.

Ask suppliers whether alternative structures are available and request relevant recyclability and food-contact documentation.

Step 2: Evaluate Product Protection Requirements

Before changing the packaging film, define the product's actual protection requirements.

Consider:

• Oxygen transmission rate (OTR).

• Water vapor transmission rate (WVTR).

• Required shelf life.

• Light sensitivity.

• Storage temperature.

• Transportation conditions.

A recyclable structure must still provide adequate protection for the food product.

Step 3: Test New Films on Existing Machines

Do not assume that a new film can run at the same settings as the original material.

Conduct machine trials to evaluate:

• Film feeding stability.

• Sealing temperature.

• Sealing time and pressure.

• Seal strength.

• Bag formation.

• Cutting accuracy.

• Production speed.

For demanding applications, trial runs should include different operating speeds and representative production conditions.

Step 4: Identify Necessary Machine Adjustments

Depending on the test results, manufacturers may need to adjust:

• Temperature controllers.

• Sealing jaws.

• Film tension settings.

• Film pulling parameters.

• Forming components.

• Cutting synchronization.

• Machine operating speed.

In some cases, existing machines can handle the new film after parameter adjustments.

In other cases, additional mechanical or sealing-system modifications may be necessary.

Step 5: Work with Film and Machinery Suppliers Together

Film suppliers understand the material's physical and sealing properties.

Machinery manufacturers understand how the film behaves during forming, transportation, sealing, and cutting.

Cooperation between the two sides can help reduce trial-and-error time and identify suitable production parameters.

It is also important to keep records of the film specification, trial conditions, seal-quality results, and final operating settings for future production.

6. What Should Manufacturers Consider When Buying New Packaging Machines?

For food manufacturers planning to invest in new packaging equipment, future film compatibility should be included in the purchasing discussion.

Instead of evaluating a machine only by its maximum packaging speed, buyers should also consider its ability to work with different film structures.

Important questions include:

1. Can the machine handle different film materials?

Confirm whether the equipment can work with the specific PE-, PP-, or other recyclable film structures being considered.

2. Is the sealing temperature adjustable?

Independent temperature control for different sealing sections helps operators optimize sealing conditions for different materials.

3. Can film tension and pulling parameters be adjusted?

Stable film transportation is important when working with flexible materials that have different mechanical characteristics.

4. Can the machine maintain accurate cutting and registration?

Accurate color-mark detection and cutting synchronization help maintain consistent package dimensions and appearance.

5. Can the supplier conduct material trials?

Before purchasing a machine, manufacturers should provide actual film samples for testing whenever possible.

The most reliable way to confirm compatibility is to run the intended film on the proposed machine and inspect the finished packages.

7. How Keypack Packaging Machines Support Flexible Film Applications

As packaging materials continue to evolve, food manufacturers need packaging equipment that can be properly adjusted to different film characteristics.

Keypack provides VFFS, HFFS, and flow wrapping solutions for food manufacturers handling different products and flexible packaging formats.

Our machines can be evaluated according to the intended film material, bag dimensions, product characteristics, and production requirements.

VFFS Packaging Machines

Vertical packaging machines are suitable for powders, granules, snacks, nuts, and other food products.

Depending on the machine configuration, they can produce pillow bags, gusseted bags, and other compatible bag styles.

Film feeding, sealing temperature, and bag-forming parameters can be evaluated according to the selected packaging material.

HFFS and Flow Wrapping Machines

Horizontal packaging machines are suitable for individual products such as biscuits, bread, confectionery, and other solid food products.

The sealing system, film transportation, and cutting mechanism can be assessed according to the required film structure and package dimensions.

Packaging Material Compatibility Testing

A packaging machine should not be considered compatible with every recyclable film simply because it has adjustable temperature controls.

Actual performance depends on the film's structure, sealing layer, thickness, friction, stiffness, and barrier requirements.

Keypack can evaluate machine configurations based on customer-provided film samples and product specifications.

Our goal is to help manufacturers identify a practical packaging solution that balances material compatibility, sealing quality, and production efficiency.

Planning to upgrade your packaging line for new flexible packaging materials?

Contact Keypack and share your current film structure, target packaging material, product dimensions, and required production speed.

Our team can help evaluate the appropriate VFFS, HFFS, or flow wrapping machine configuration for your application.