NOVAPLEX® 5-Layer Sustainable PE Film
Sustainable PE Film - 100% Recyclable Packaging Solution
A new generation 5-layer Polyethylene film solution that fully meets the Design for Recycling (D4R) orientation, Extended Producer Responsibility (EPR) standards, and the European Packaging and Packaging Waste Regulation (PPWR). NOVAPLEX® Sustainable PE Film helps FMCG brands and packaging factories minimize their Carbon Footprint while fully maintaining mechanical properties, stiffness, and high-speed heat sealing performance.
Industry Context & Green Packaging Transition Trend
The global flexible packaging industry is undergoing a historic shift towards Circular Economy. Traditional multilayer structures (such as PET/PE, OPP/PE, PA/PE) are facing enormous recycling challenges due to the inability to separate incompatible plastic layers. Meanwhile, global consumer brands have strongly committed to using 100% Recyclable, Reusable, or Compostable packaging by 2025 - 2030.
Three Technical Breakthroughs in NOVAPLEX® Sustainable PE Film
1. 100% Recyclable Mono-Material Structure (Recyclable Mono-PE Structure)
To replace traditional laminated structures that are difficult to recycle, NOVAPLEX® provides a specialized 5-layer PE film for laminating with oriented PE film (MDO-PE or BOPE). The result creates a packaging structure entirely from Polyethylene (100% Mono-PE). Used packaging can be collected, shredded, and fed directly into the industrial PE recycling stream (Plastic Recycling Stream Code 4 LDPE) without going through complex chemical separation processes, achieving Design for Recycling (D4R) certification.
2. PCR & PIR Recycled Resin Integration in a Safe Core Layer
Thanks to independent 5-layer co-extrusion technology (A/B/C/D/E), NOVAPLEX® thoroughly solves the difficult problem of using recycled plastics: how to increase recycled content while ensuring food safety hygiene and keeping the film surface flat and smooth.
- Functional Barrier structure: PCR (Post-Consumer Recycled) or PIR (Post-Industrial Recycled) resin is scientifically blended and completely hidden in the Core Layer (Layer C, accounting for 30% of total film thickness).
- Protected by 100% genuine virgin resin: The two outer surface layers (Layer A & Layer E) and two structural layers (Layer B & Layer D) act as absolute functional barriers, extruded with 100% high-tech virgin Polyethylene resin. This ensures the innermost film layer contacting food fully meets FSSC 22000, ISO 9001:2026, and QCVN 12-1:2011/BYT hygiene standards.
3. Downgauging Solution (Less is More)
Besides using recycled plastic, the most effective sustainable solution is reducing the amount of plastic used right from the start. By blending new-generation Polyethylene resins with special molecular weights and high toughness, NOVAPLEX® 5-layer PE film allows reducing thickness by 10% to 20% (e.g., from 50µm to 40µm or 35µm) while maintaining impact resistance, puncture resistance, and heat seal strength. Downgauging helps businesses directly reduce plastic emission weight and optimize BOM costs.
Sustainable Functional Allocation 5-Layer Structure (A/B/C/D/E)
NOVAPLEX® Sustainable PE Film is designed with a balanced symmetrical 5-layer structure, optimizing functions for each layer position using 100% virgin resin combined with selected recycled resin:
| Film Layer | Thickness Ratio / Material | Technical Function & Sustainable Value |
|---|---|---|
| Layer A (Outer Skin) | 15% - 100% Virgin Resin | Durable Corona treatment 38–42 Dynes/cm. Absolutely smooth surface, sharp ink and lamination glue adhesion, impurity-free. |
| Layer B (Sub-skin) | 20% - 100% Virgin Resin | Structural layer increasing flexural modulus stiffness. Acts as an outer functional barrier protecting the recycled core layer. |
| Layer C (Core Layer) | 30% - 20%~80% Recycled Resin (PCR/PIR) | Central core layer hiding selected PCR/PIR recycled plastic. Optimizes the plastic waste lifecycle, reduces Carbon emissions, and lowers production costs. |
| Layer D (Sub-skin) | 20% - 100% Virgin Resin | Symmetrical stress balance with Layer B, preventing film curling. Acts as an inner functional barrier. |
| Layer E (Inner Sealant) | 15% - 100% Virgin Resin | Low-temperature heat sealing surface (Low SIT). Meets FSSC 22000 & QCVN 12-1:2011/BYT food contact safety standards, instant sealing. |
Diverse Sustainable Solutions & Export Industry Applications
1. 100% Recyclable Mono-PE Stand-up Pouch
NOVAPLEX® 5-layer PE film combined with MDO-PE film creates 100% PE Stand-up Pouches or Spout Pouches. This is a perfect alternative to PET/PE packaging for dry foods, cereals, coffee, detergent, and refill shampoo, helping FMCG corporations easily achieve the goal of 100% recyclable packaging commitments by 2030.
2. Consumer Goods & Green Supermarket Bags with Integrated PCR/PIR
The 5-layer PE film line containing 30% - 50% PCR/PIR recycled resin in the core layer is an ideal choice for non-direct contact or secondary packaging applications such as: diaper wrapping film, sanitary napkins, beverage shrink film, supermarket shopping bags, and e-commerce packaging bags. The product helps improve ESG assessment scores for businesses.
3. Recycled Frozen Food Packaging (-25°C)
Thanks to flexible blending of tough virgin Polyethylene resin in the surface layers, NOVAPLEX® sustainable PE film still maintains the ability to withstand deep freezing temperatures (-18°C to -25°C), outstanding Dart Drop impact resistance, prevents micro-punctures from fish fins or sharp corners of frozen foods, fully meeting standards for packaging seafood exported to European and US markets.
Standardized Quality Management Process & B2B Commitments
DNC Film commits to providing NOVAPLEX® Sustainable PE Film with the highest quality stability through an international standard management system:
- Standardized manufacturing plant in Tay Ninh: Operated under strict dust and insect control processes, achieving FSSC 22000 (Category I) and ISO 9001:2026 certifications.
- Auto-Gauge automatic thickness control system: Controls extremely small uniform thickness tolerances (2-sigma ≤ ±5.0%), keeping the film flat, preventing print misregistration or curling during lamination.
- Clear recycled plastic traceability: The PCR/PIR recycled resin source is independently verified, with certificates of origin and a closed-loop impurity filtering process, ensuring no impact on customers' lamination lines.
- R&D engineers customizing formulas: Ready to coordinate with partners' R&D departments to design the optimal recycled plastic ratio (20% - 80%) and thickness exactly suited to the VFFS/HFFS packaging machine speeds of each factory.