Mono-material: why mono-material changes packaging choices.
An early decision on membrane structure can determine whether your packaging is recyclable.
Mono-material packaging is made almost entirely from a single type of plastic, such as all PE or all PP, allowing sorting machines to recognize and process it. This is important because multi-layer laminated films mixed with various plastics are nearly impossible to recycle mechanically, while mono-material structures yield higher quality recycled pellets and are accepted by recovery systems. This is the strongly recommended design direction for consumer flexible packaging today.
- products that do not require high barriers
- want to recycle well and use high-quality recycled materials
- review the code list to find codes that can be converted to material units
- products that are extremely sensitive, like roasted coffee, need absolute oxygen barrier
- add a barrier layer exceeding recycling limits
When you choose flexible packaging for your product, the most important decision is not the print color or shape, but the structure of the film. Traditional laminated films mix different types of plastics in one packaging sheet, making them nearly impossible to recycle with existing mechanical technology. Mono-material design, or single material, is the reverse approach: keeping the entire structure within one type of plastic so that sorting machines can recognize it, and recycling systems can process it.
How does the material unit function?
A packaging film typically has multiple functional layers combined: an outer layer for printing, a middle layer for rigidity or gas barrier, and an inner layer in contact with food. Traditional laminates often use PET (polyethylene terephthalate) for the outer layer, then laminate with PE (polyethylene) for the inner layer. These two types of plastics cannot be separated during mechanical recycling, so the entire film must be discarded.
A single material structure addresses this issue by using the same family of plastics for all layers, such as PE/PE or PP/PP. Functional coatings and barrier layers (gas and moisture barriers) are still allowed, but must remain within the threshold that does not contaminate the recycling stream. The D4ACE guidelines from CEFLEX (an organization promoting a circular economy for flexible packaging in Europe) set a minimum threshold: at least 90% of the structure must be single-target material to be considered recyclable.
Why the 90% threshold is important for design
The 90% threshold is not an arbitrary number. This is the point at which optical sorting machines and mechanical recycling lines can handle the structure without contaminating the output recycled material. Below this threshold, the recycled material is of poor quality, cannot be sold to other manufacturers, and the entire material value is lost.
This means, in practical terms, that a small barrier layer is added to increase gas barrier properties; if the ratio of materials outside the main plastic exceeds 10%, it will compromise the entire recyclability of the packaging. This is the most common mistake Sinh Vũ encounters when reviewing film structures for clients: the packaging looks "almost right" but actually does not meet the threshold due to a seemingly minor coating.
When to choose single material, when to keep the composite film
Select single material when: the product does not require extreme oxygen or moisture barriers, or when that requirement can be met with a coating within 10%. For example: dry food bags, snack bags, solid cosmetic packaging, non-food product bags. This group often has opportunities for conversion without compromising product protection.
Keep the barrier film when: the product is extremely sensitive and requires near-absolute oxygen barrier, such as roasted coffee, processed meat, or long-shelf-life foods that depend on strict packaging conditions. In this case, prioritizing product preservation is more important, and multi-layer barrier films remain a practical choice until high-barrier single-material technology matures.
Single-source polyolefin materials (PE, PP) are preferred over blended materials because they provide the best classification and recovery, while also yielding higher quality recycled pellets for re-entering production.
CEFLEX D4ACE Design Principles
Common mistakes when misunderstanding concepts
- Thinking all plastic packaging is recyclable. Plastic is a broad material, consisting of many different families. Laminates that mix PET with PE cannot be mechanically recycled, even though both are familiar plastics.
- Confusing material unit with a single layer. A material unit can have multiple layers, as long as those layers belong to the same plastic family and the total outer ratio does not exceed the threshold.
- Changing the structure without checking the product. Switching to a single material without verifying its protective capabilities can shorten shelf life or damage goods during transport.
- To decide on materials after finalizing graphic design. The structure of the film must be determined before the printing design, as it affects the outer layer, color printing capability, and surface texture.
The viewpoint of Sinh Vũ
When you want to move towards sustainability, Sinh Vũ does not suggest changing the entire portfolio at once. The practical approach is to review each code: codes that require moderate protection can be placed in the group that can immediately order materials, while sensitive items should remain unchanged and be noted for reconsideration when technology allows.
This decision is a technical material choice, not a graphic decision. It needs to be aligned with the actual capabilities of the partner printing house, as not every workshop has access to high-quality single-layer materials, and costs and supply capabilities will vary. Sinh Vũ works with clients at this stage before finalizing any designs to avoid situations where the design looks good but cannot be printed, or can be printed but the packaging does not meet the promised criteria.
Decision checklist
Topic: What is mono-material and why is it important. Sinh Vũ guide, sinhvu.com
Select each item you find appropriate, then print or save as PDF to take with you.
If you have marked most of the signs above, this is the time to discuss in more detail. Sinh Vũ can help you review and propose a direction.
References
CEFLEX D4ACE Guidelines, Design Principles and Design Choices (high reliability). Packaging Europe, article reporting on CEFLEX's mono-material recommendations. Sinh Vũ's practical experience in designing and operating flexible packaging brands.
Frequently asked questions
Does a material unit mean the packaging has only one layer?
No. A material specification does not mean a single layer but the entire structure belonging to a family of plastics, such as PE/PE or PP/PP. Packaging can still have multiple functional layers, coatings, or barriers, as long as those layers do not introduce materials outside the main plastic family beyond the allowed threshold. The CEFLEX D4ACE guidelines set a minimum threshold of 90% for the structure to be considered recyclable.
If switching to a material unit, will the packaging provide less protection for the product?
Depending on the product. For items that are not overly sensitive to moisture and oxygen, a material combination with a functional coating within permissible limits is still sufficient protection. For extremely sensitive items like roasted coffee or food that requires near absolute oxygen barrier, multi-layer films may still be a more practical choice. Each SKU needs to be tested; do not generalize conclusions for the entire category.
Does Vietnam's recycling infrastructure accept PE or PP material orders?
The recycling and composting infrastructure in Vietnam is developing and uneven across regions. However, the decision to design with single materials is still valuable today for two reasons: products can be exported to markets with better infrastructure, and domestic infrastructure will gradually improve. Designing correctly from the start is less costly than redesigning after mass printing.