Key insights from our expert web seminar with Dr. Heiko Schenck
Polyethylene (PE) remains one of the most important materials in the packaging industry—yet its diversity has increased significantly over the past decades. In the web seminar “The World of Polyethylenes – Which PE for Which Purpose?”, participants gained a comprehensive and practice-oriented overview of modern polyethylene types, processing technologies, and applications. The seminar was presented by Heiko Schenck, polymer chemist and long-standing industry expert, in cooperation with Innoform Coaching GmbH.
From simple categories to a complex material family
In the early days, polyethylene could be divided into just a few groups: LDPE, HDPE, and later LLDPE. Today, the picture is much more differentiated. Medium‑density grades, very‑low‑density PE, plastomers, metallocene‑based PE, bimodal grades, and oriented polyethylene films have expanded the material portfolio significantly.
A key message of the seminar was clear: when selecting polyethylene, density matters more than naming conventions. While designations can be misleading, density provides reliable insight into stiffness, sealability, processing behavior, and end‑use performance.
Innovation drivers: down‑gauging, machinery, and collaboration
One of the strongest innovation drivers in polyethylene development is light‑weighting (down‑gauging). Especially in Europe, this has been accelerated by long‑standing Extended Producer Responsibility (EPR) schemes and increasing sustainability requirements.
The seminar highlighted how innovation is no longer driven by polymer producers alone. Instead, close collaboration between material suppliers, machinery manufacturers, and converters has become essential. Modern multi‑layer extrusion lines, advanced cast and blown film technologies, and optimized material combinations enable thinner films while maintaining or even improving performance.
Processing technologies: blown, cast, and oriented films
Participants received a clear overview of today’s processing landscape:
- Blown film remains highly relevant, especially for transport packaging and many established structures.
- Cast film technology offers significantly higher output rates and cost advantages, particularly for PA/PE and PET/PE structures.
- Oriented polyethylene films (MDO‑PE and BOPE) are among the most dynamic developments. These materials enable mono‑material packaging solutions that support recyclability goals while still meeting demanding mechanical and shelf‑life requirements.
Special attention was given to orientation technologies, including MDO, double‑bubble, triple‑bubble, and tenter‑frame processes—each with distinct advantages and limitations depending on application and structure design.
Sealants and performance: why co‑monomers matter
A central technical focus of the seminar was polyethylene as a sealant. Here, co‑monomer type and level play a decisive role:
- Higher co‑monomer content lowers crystallinity and seal initiation temperature.
- Metallocene‑based LLDPE and plastomers enable stronger seals, wider sealing windows, better hot‑tack, and improved sealing through contamination.
- In many cases, higher‑performance (and higher‑priced) sealants lead to overall cost savings by enabling higher packaging line speeds and reduced waste.
The conclusion: material selection must always consider the packaging machine, line speed, and real‑life contamination conditions, not just laboratory data.
Recycling and sustainability in practice
Recyclability was addressed throughout the seminar, especially in relation to mono‑material concepts and non‑food packaging. For many industrial and transport packaging applications, polyethylene‑rich structures already allow:
- Efficient mechanical recycling
- Integration of in‑house recyclates or PCR material, typically in bulk or core layers
- Continued performance without compromising product protection
The seminar emphasized that product protection and food waste reduction remain the top priority—sustainability solutions must never weaken packaging performance.
Practical value and lively exchange
The seminar included a dedicated Q&A session with in‑depth questions on cast film structures, cost optimization, and the use of recycled materials. The lively exchange once again demonstrated how relevant and application‑driven the topic of polyethylene has become for the industry.
Key takeaways at a glance
- Polyethylene diversity has increased significantly—density is the key selection criterion
- Down‑gauging and orientation technologies are major innovation drivers
- Sealant performance depends strongly on co‑monomer type and level
- Modern PE structures support recyclability without sacrificing performance
- Collaboration across the value chain is essential for future packaging solutions
With this web seminar, we are further strengthening our claim to be the leading knowledge partner in the field of flexible packaging – both through our Testing Service in Oldenburg and through Innoform Coaching.