Duo develops ‘never seen before’ packaging film

A Manchester-based manufacturer has developed a “next generation” material aimed at reducing plastic use and increasing recycled content in flexible packaging.

Duo Packaging has created graphene-enhanced film 2DPE in partnership with the University of Manchester’s Graphene Engineering Innovation Centre (GEIC).

The material is designed to retain tensile strength and tear properties while allowing manufacturers to use more recycled content, reduce material consumption and improve processing and energy efficiency.

Industrial trials involving GEIC and live shopping retailer QVC found the graphene-enhanced polythene film increased material strength by up to 35 per cent and allowed recycled content to rise from 45 to 60 per cent.

QVC also recorded a 15-degree reduction in the heat-sealing temperature required and has now switched from standard autobagging film to 2DPE at its Liverpool fulfilment centre.

The move is expected to save around 50 tonnes of virgin plastic annually, while trials also allowed film thickness to be reduced from 30 to 28 microns.

Duo says the resulting five per cent reduction in weight could save QVC around £21,150 a year in packaging Extended Producer Responsibility fees.

Zoe Brimelow, Duo co-owner and brand director, who led the research partnership and development of 2DPETM, said: “To effectively improve packaging sustainability, businesses need solutions that are commercially and operationally viable. 

“Retailers are facing cost pressures, tightening regulations, growing customer expectations, market volatility and supply chain challenges. 

“There was nothing on the market that could solve all of these challenges without having to make some type of trade-off. 

“We knew graphene was the answer to solving this challenge.

“We’ve spent over a year on research and development, ensuring we can commercialise this innovation and create the next generation of flexible packaging. 

“The focus is now on working in partnership with retailers and consumer brands to apply this new technology to their packaging. 

“Every application will be different, presenting exciting opportunities to increase the levels of recycled content in flexible packaging, reduce material weight, consumption and carbon, and doing all of this without compromising operational performance or customer experience.”

Dale Brimelow, Duo co-owner and operations director, added: “The packaging industry is undergoing huge change, and one of the most significant drivers is the EU’s Packaging and Packaging Waste Regulation (PPWR). 

“This impacts UK businesses selling in the Union and is seeing a much wider shift in the standardisation of packaging beyond the EU.

“There is growing demand for packaging that is recyclable, uses higher levels of recycled content, uses resources more efficiently and is lightweight by design. 

“At the same time, businesses have to protect product integrity, maintain operational efficiency and manage costs. 

“Utilising graphene will transform the application of flexible packaging to meet this demand and has created an advanced material that’s fit for the circular economy.”

Initially being used for e-commerce mailing bags and autobagging film, 2DPE was developed with funding through the Innovation Navigator Programme.

Mark Dickie, applications manager of the Graphene Engineering Innovation Centre, added: “We’re involved in hundreds of projects every year, which translate graphene into real-world technologies and support commercial deployment. 

“Duo’s innovation is delivering something we’ve never seen before in flexible packaging and has created an advanced material that can support retailers to transition to a circular economy.

“2DPETM is an excellent example of how graphene’s strength, durability and lightweight performance can be utilised to significantly enhance an everyday product. 

“In this case, application of nanotechnology creates new possibilities for improving environmental and operational performance throughout retail supply chains.”  

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