New Recyclable Metallized PE Film from Pregis

Marking five years since launching one of the first recyclable barrier films, Pregis Performance Flexibles has developed solutions for a broad range of barrier packaging applications.

It's been five years since introducing one of the first EVOH (ethylene vinyl alcohol) barrier sealant films designed for store drop-off recycling. The company will highlight its Performance Flexibles portfolio, including a new metallized polyethylene high-barrier sealant film, at Pack Expo International 2026, Oct. 18 to 21 at McCormick Place in Chicago, booth S-3874.

Five years ago, a barrier structure eligible for store drop-off recycling was not a practical option for most flexible packaging applications. Pregis took a mono-material polyethylene approach, developing films that run on existing converting and filling equipment while remaining eligible for store drop-off recycling. Its portfolio now includes downgauging and recycled-content technologies that enable brands to select recyclable structures without re-engineering their packaging operations.

New Addition: metallized PE high-barrier sealant film

Pregis introduces an ultra-high-barrier, mono-material metallized PE (polyethylene) sealant film developed for applications that have historically required metallized OPP (oriented polypropylene) or metallized PET (polyethylene terephthalate). The film delivers barrier performance and processability comparable to legacy materials and is prequalified as store drop-off recyclable through How2Recycle^®.

For coffee, snack, pet food and other food packaging categories that depend on high barrier, it removes one of the last technical reasons to keep a mixed-material structure in the specification.

"Every one of these structures started with a customer telling us what they could not give up, whether that was shelf life, line speed or a particular package format," said Bob Gargione, President, Performance Flexibles, Pregis. "Our job was to deliver a recycle-ready answer that performed the same way on their equipment. Now, five years in, the portfolio is broad enough that recyclability is no longer the tradeoff it used to be, and that matters more every time another state enacts EPR regulation."

The pace of that work is being set by legislation. Extended producer responsibility (EPR) programs are now moving state by state across the United States, with fees tied to factors including recyclability, post-consumer recycled (PCR) content and other attributes. Pregis is developing its flexible packaging portfolio so that customers can meet those requirements as they take effect, rather than reformulating packaging under deadline pressure.

Downgauging with the U-Series

The Pregis U-Series ultra-high-durability sealant film is engineered to remove nylon from the packaging structure, the component that prevents recycling in conventional high-barrier films, while preserving the barrier and durability performance brands depend on. Running at a thin gauge, it also lets customers downgauge conventional high-barrier structures, reducing material use, carbon footprint and the volume subject to EPR fees.

Recycled content and the Renew Series

The Pregis Performance Flexibles Renew™ Series of sustainable flexible packaging materials has evolved around four principles: recyclability, renewable inputs, recycled content and material reduction. The new metallized PE high-barrier sealant film and the U-Series are both part of the Renew™ portfolio.

Pregis was named an Association of Plastic Recyclers Demand Champion for its commitment to incorporating post-consumer recycled content, sourced from the highest-quality North American PCR available, and is partnering with organizations across the industry to develop bio-resin solutions for brands and consumers who want renewable inputs in their packaging.

The Pregis blown-film extrusion facility in Anderson, South Carolina, achieved 99 percent waste diversion from landfill in 2024 and 2025, and Pregis holds ISCC PLUS certification at multiple facilities globally, supporting the chain of custody behind circular and bio-based resin claims.

Learn more about Pregis Performance Flexibles at Pack Expo International 2026, booth S-3874. Pregis flexible packaging specialists will be available throughout the show, and packaging decision-makers can schedule a meeting at www.pregis.com/pack-expo.

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