ExxonMobil develops thermoformed packaging with 95 percent PE content

ExxonMobil, working with key partners, has developed a fully recyclable thermoformed packaging product featuring 95 percent polyethylene (PE) content. The Houston-based energy company says the new packaging design offers a high oxygen barrier, “excellent” optics and enhanced puncture resistance while maintaining optimized formability for hot fill and aseptic applications in the food and beverage sectors.

ExxonMobil's package comprises a thermoformed bottom web and machine direction oriented (MDO) PE lid film, both engineered with the company’s premium resins such as Exceed XP, Enable and Exact plastomers, along with Eval Evoh resins for barrier properties.

The collaboration utilized barrier lines developed by the Germany-based Hosokawa Alpine Group for the production of these films, delivering what ExxonMobil calls a “durable and recyclable solution that meets modern packaging requirements for sustainability without sacrificing performance.”

To further enhance the packaging’s environmental credentials, ExxonMobil says its design minimizes material usage while still offering superior protection and sealing properties. By reducing the overall weight and maximizing recyclability, the company says its new solution not only supports sustainability goals but also helps converters and brand owners meet increasingly stringent regulations on plastic packaging scrap and recycling targets.

The new packaging was successfully tested on Germany-based Multivac’s R245 machine, ExxonMobil says, achieving “excellent” machinability with high line speeds and ensuring the integrity of the package even under rigorous conditions.

“This innovation aligns with the industry’s shift toward more sustainable, circular packaging solutions that reduce environmental impact while ensuring product protection,” the company says.