Creating barrier packaging for a circular economy with EVAL™ EVOH How EVAL™ EVOH supports you in the development of circular packaging
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TABLE OF CONTENTS
Introduction
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1 Facing new packaging challenges
Meeting new packaging demands: How EVAL™ EVOH delivers sustainability without compromise
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How EVAL™ EVOH enables you to solve your packaging challenges . . . . . . 6
— Mono-material packaging: easy to recycle . . . . . . . . . . . . . . . . . . . . . . . . 7 — Optimising existing plastic packaging structures . . . . . . . . . . . . . . . . . . 8 —Exploringfibre-basedpackaging.................................9
2 Preventing waste
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The packaging world needs to change: consumers, brand owners and legislators demand circularity. Packaging must be recyclable and wasting resources is no longer an option. EVAL™ EVOH is here to bring solutions and tackle key sustainability challenges of the food packaging industry. This polymer helps create recycle-ready – PPWR compliant – barrier packaging, prevents both packaging and food waste and lowers the supply chain’s carbon footprint. We will explore sustainable solutions for your packaging and look at ways to prevent both packaging and food waste. And we will share some of our initiatives that make our company and product more sustainable.
Extending shelf life to prevent food waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Preventing overpacking to reduce packaging waste . . . . . . . . . . . . . . . . . . . . 12
3 Reducing your carbon footprint
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ISCC PLUS certified ................................................ 15 How a mono-material structure can drastically reduce your carbon footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Innovation-driven collaborations 5 Our commitment to sustainability
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Let us work towards a more sustainable future together.
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Our mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 EVAL Europe N.V.’s sustainable initiatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Working towards a sustainable future
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The Packaging and Packaging Waste Regulation (PPWR) is disrupting the packaging industry. In short, this EU-wide legislation:
• Aims to minimise the environmental impact of packaging. • Aims to reduce resource consumption and packaging waste. • Requires all packaging sold in the EU to be recyclable by 2030. • Explicitly calls for circular plastic packaging with design-for-recycling criteria.
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Facing new packaging challenges 1
The PPWR is reshaping the entire packaging industry, forcing converters and brand owners to fundamentally rethink their approach to packaging.
For converters , the PPWR mandates significant changes in packaging design and production processes. Packaging must be minimised in weight and volume, made from recyclable, reusable or compostable materials and meet strict requirements for recycled content and hazardous substances such as PFAS. This compels converters to invest in new materials, redesign product lines and adopt innovative, circular economy models to remain compliant and competitive. For brand owners , this means that when they bring packaged goods to market in the EU, they now have the responsibility to ensure that these meet the new recyclability and sustainability criteria. Otherwise, they risk losing access to the EU market. This affects procurement, R&D and marketing strategies, challenging companies to rethink packaging choices, supply chain partnerships and reporting systems. Non-compliance can result in higher fees or exclusion from the market, while compliance offers opportunities for cost savings, access to eco-conscious consumers and enhanced brand reputation. To drive eco-friendly designs, Extended Producer Responsibility (EPR) fees and plastic taxes are coming into play. Brand owners placing packaged food on the EU market handle EPR fees, which can vary widely in cost and territory. Interestingly, these fees are not specific to Europe – some American states and countries in the Middle East also maintain them. Strong incentives are driving the barrier packaging industry toward sustainable and circular packaging – without eliminating the primary function of packaging, which is to avoid food waste.
Let us explore how using EVAL™ EVOH can help.
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MONO-MATERIAL PACKAGING: EASY TO RECYCLE Multi-material packaging that is made from different types of materials is difficult or impossible to recycle because separating the layers is technically and economically challenging. Mono-material packaging avoids this issue and will play a key role in the future because it is easier to recycle. Several recycling organisations all over the world have issued recycling recommendations highlighting the advantages of mono-material structures. More specifically, mono-material packaging – made primarily from a single polymer like PE or PP – is easier to recycle than multi-layer composites (e.g., plastic-aluminium or plastic-paper), which are often non-recyclable. EVAL™ EVOH, used in thin layers (≤10%), provides high-performance oxygen barriers while maintaining recyclability:
To help producers meet PPWR requirements, recycling organisations have published guidelines. In general, they recommend structures with over 90% of a single polymer type , and EVOH stands out as the preferred barrier material in polyolefin recycling streams. There are three ways in which EVAL™ EVOH can help you design packaging that is in line with the recyclability, reusability and minimal waste principles of the PPWR. How EVAL™ EVOH enables you to solve your packaging challenges
• It is recognized by recyclability guidelines as non-disruptive to recycling streams • It is compatible with both mechanical and chemical recycling, offering a full end-of-life solution
Mono-material structures typically consider to meet grade A or B recyclability performance grades set by the PPWR regulation, especially when barrier layers like EVAL™ EVOH are kept below 10% of total weight.
1. Mono-material packaging — We can help you find a mono-material alternative for traditional multi-material packaging.
2. Optimise your packaging — If you are already using EVAL™ EVOH in your packaging, we can help you with down-gauging or structure optimisation.
3. Paperisation — Add a thin layer (5% or less) of EVAL™ EVOH to fibre-based packaging to create an effective barrier and maintain recyclability.
Facing new packaging challenges — 7
6 — Facing new packaging challenges
OPTIMISING EXISTING PLASTIC PACKAGING STRUCTURES
Redesigning packaging means striking the right balance between protection, minimal material use and recyclability. EVAL™ EVOH offers a lot of performance in tiny amounts of material, adding vital barrier function to the entire package. If your packaging already contains EVAL™ EVOH, we can advise you on down- gauging . Selecting an EVAL™ EVOH grade with a lower ethylene molar percent can reduce the percentage of EVAL™ EVOH to 5% by weight or less, making your packaging comply with the most stringent current recycling guidelines – without losing efficiency. The packaging will retain its oxygen barrier performance and have the same shelf life. As an added benefit, it will reduce your cost and lower your carbon footprint.
EXPLORING FIBRE-BASED PACKAGING Another way to meet the PPWR regulation is by choosing fibre-based packaging. However, a barrier is still needed to extend shelf life and to prevent contamination (using EVOH) and moisture (using PE). Combining a thin layer of EVAL™ EVOH and a PE layer with consumer-preferred paper packaging is a possible solution.
Example of a down-gauging opportunity with low ethylene grades*
Research according to 4evergreen* standards has shown that EVAL™ EVOH:
• will not disrupt the paper recycling stream, • will not end up in the wastewater, • will not affect the quality of the recycled paper (no impurities or adhesion).
PE
PE
PE
As consumers increasingly tend to favor paper-based packaging, its use is becoming widespread in various applications such as food and cosmetic packaging.
7.6% (EVAL TM 32 mol%)
5.2% (EVAL TM 29 mol%)
100µm
3.4% (EVAL TM 27 mol%)
PE
PE
PE
*4evergreen is a cross-industry alliance dedicated to developing tools and guidelines for an even more sustainable sector, aiming for consistency across Europe’s recycling practices.
Ready-to- recycle
*EVOH (wt%) in 100μm PE/EVOH/PE film to maintain an OTR level of 1cc/m2,day,atm. Based on Kuraray data (cast film), at 20°C 65%RH.
— Different grades of EVAL™ EVOH Kuraray’s specialists have created the world’s widest range of EVOH grades by varying the ratio of ethylene and vinyl alcohol in the copolymer. Each grade has specific applications. Generally, a lower ethylene content means better barrier properties.
SC
24% 27% 32% 38% 44% 48%
mol% ethylene 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
M L
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H
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T J
Available types of EVAL™ resin
Facing new packaging challenges — 9
8 — Facing new packaging challenges
2 Preventing waste
Negative environmental impact
Packaging waste
Optimum pack design
Food waste
Minimum environmental impact
Overpacking
Underpacking
Minimum material
Increasing packaging material weight or volume
Optimum pack design
a. At required oxygen (gas) barrier O 2GTR b. With lowest carbon footprint # kg CO 2 /kg c. Recyclable according to PPWR design-for-recycling criteria d. Optimal cost of packaging structure
VALUE of EVAL TM EVOH in mono-material packaging (€)
Extending shelf life to prevent food waste
In the push for a sustainable future and circular economy, reducing both food and packaging waste is essential. Apart from helping you create effective, recycle-ready food packaging, EVAL™ EVOH can help you in two more ways:
Plastics can play an important part in the sustainable use of the world’s natural resources. Modern plastic packaging keeps food fresh for longer, protects the food during transport and helps avoid waste. Food waste impacts the environment because it squanders the resources used to produce, process, package and transport the food. Shelf life extension is one of the most effective strategies to avoid food waste. EVAL™ EVOH excels at blocking oxygen, but also maintains aroma and modified atmosphere and guards against grease and outside odours. It also prevents contamination from, for example, MOSH/MOAH mineral oils. Your perfect companion to keep your food fresh and prevent food waste. Plus, the right packaging allows for more efficient use of food, better distribution, and less waste , both at retail and consumer levels. The FAO (Food and Agriculture Organization of the United Nations) estimates that 1/3 of all food production is lost due to loss or spoilage*. Using functional packaging in the correct portion size is a great way to reduce waste and save resources.
• Extending shelf life to prevent food waste
• Preventing overpacking to reduce packaging waste
* https://www.ofi.at/projekte/stop-waste-save-food
Preventing waste — 11
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Contamination
Oxygen
Odours
Outer layer Regrind
Tie
EVAL™ EVOH
Tie Inner layer
Freshness
Aroma
Modified atmosphere
Preventing overpacking to reduce packaging waste To reduce packaging waste, it is important to prevent overpacking. If you want to prevent overpacking, EVAL™ EVOH can help you achieve the optimum balance between protection, minimal material use and recyclability. A noteworthy trend is a transition from rigid structures (such as tubes, trays and jars) to flexible structures (such as stand-up pouches, sachets, flow packs, shrink film, ...) , which can be created
using EVAL™ EVOH. These flexible structures can be adapted to just the right sizes, shapes and proportions. You will need less material and boost sustainability. For example, a barrier stand-up pouch can perform as glass, metal or hybrid structures, using much less material. However, always keep in mind that consumer convenience is key. Sometimes it is best to transition to flexible structures – and sometimes optimising your existing rigid structure is the way to go. Further savings may originate from EVAL™ EVOH’s low material footprint and energy conservation during processing and distribution . Lighter, smartly designed packaging means fewer trucks on the road.
Preventing waste — 13
12 — Preventing waste
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Production process in the chemical industry
Circular or bio-based feedstocks
Physically mixed materials
Final products
Fossil feedstocks
HOW A MONO-MATERIAL STRUCTURE CAN DRASTICALLY REDUCE YOUR CARBON FOOTPRINT Choosing mono-material packaging with a thin layer of EVAL™ EVOH can help you reduce your carbon footprint drastically. Using PIQET 4.2.3, Kuraray Co. Ltd. calculated the carbon footprint (CFP) for an aluminium foil structure, a VM-PET structure and a (mono-material) VM-EVOH-BOPP structure.
The VM-EVOH-BOPP structure’s carbon footprint was the lowest, with a relative impact of 56% compared to 62% for the VM-PET structure and 100% for the aluminium foil structure. EVAL Europe N.V. is also investing in electricity from renewable resources.
Reducing your carbon footprint
Carbon Footprint (kg CO₂ eq./m )
Raw materials and processing
End of life
100%
100% 80% 60% 40% 20% 0% -20%
Effective and sustainable packaging requires a holistic view of the entire life cycle. The materials used in production should have a minimal impact on the environment and the carbon footprint should be as low as possible. ISCC PLUS CERTIFIED That is why we are able to offer the market reduced fossil-based, non-renewable raw materials in the production process of EVAL™ EVOH.
Since 2022, EVAL Europe N.V. holds the ISCC PLUS renewable resource certification for all EVOH grades produced by Kuraray in Antwerp, meaning they can be bio-circular. This shift boosts the sustainability of both our processes and your packaging. In the chemical industry, the starting products (bio-based and fossil feedstocks) are normally blended in the production complex. ISCC PLUS certification uses a mass balance approach (segregation of bio-based raw materials or reduced use of raw materials in book-keeping), which allows tracking of material flows in the complex value chain.
62%
56%
-11%
Aluminium foil structure
VM-PET structure
VM-EVOH-BOPP structure
Analysis by Kuraray Co., ltd. using PIQET 4.2.3
ASSUMPTIONS:
• Aluminium foil structure: BOPET//Al Foil//LLDPE = 12//7//70 µm (EOL: Landfill) • VM-PET structure: BOPP//VM-PET//LLDPE = 20//12//60 µm (EOL: Landfill) • VM-EVOH-BOPP structure: BOPP//VM-(EVOH)-OPP//CPP = 20//18(1)//50 µm (EOL: Recycle) This calculation includes only raw material, processing and end of life as the scope of evaluation. The calculation value are based on the amount of activity and Green House Gas (GHG) emission factor information available at the time of calculation. These are not guaranteed values.
Reducing your carbon footprint — 15
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On the road to sustainability, collaboration is key. We partner with industry leaders – bringing together advanced materials and expertise across the value chain – to develop innovative barrier packaging solutions. These solutions demonstrate that regulatory compliance and functional performance go hand in hand, empowering brand owners and converters to transition towards a more sustainable barrier packaging future. In EVAL Europe’s Application Lab, a dedicated team of technical experts and equipment will help you optimise your packaging structure to design smart and recycle-ready packaging. Read more on: https://eval.kuraray.com/en-emea/services/recycle-ready-design-support/ .
Innovation- driven collaborations 4
We also participate in alliances and initiatives – such as RecyClass, CEFLEX, 4evergreen and Plastics Europe – to make our industry sustainable and more circular. For example, we recently received the Operation Clean Sweep (OCS) certificate, recognising our efforts to prevent resin pellet loss into the environment. You can find more information here: https://eval.kuraray.com/en-emea/about-us/sustainability/our-partnerships/ .
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Innovation-driven collaborations — 17
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While we assist you in finding sustainable packaging solutions, you might wonder about our own efforts. EVAL™ EVOH is produced at several sites, including EVAL Europe N.V. in Antwerp (Belgium), part of the Kuraray Group. Kuraray aims to make its processes and supply chain more sustainable. As a group, we are committed to developing new fields of business using pioneering technology that improves the environment and enhances the quality of life throughout the world. Our commitment to sustainability 5
Our mission At Kuraray, we believe sustainability is a necessity and an opportunity. That is why we aim to improve the environment and quality of life with unique products and clean technologies. To guide us in these ambitions, we have adopted the 3P model, which centres around planet, product and people: • Planet: Improving the global environment by making effective use of resources and minimising environmental impact. Our long-term goal is to achieve net-zero carbon emissions by 2050. For scope 1 and 2, we will reduce GHG (greenhouse gas) emissions with 63% by 2035 compared to 2021. For scope 3 emissions, we are working towards a new target of reducing CO₂ with 37.5% by 2035 compared to our fiscal year 2021. Furthermore, the Kuraray Group aims to obtain SBT (Science Based Targets)* certification for its GHG emission reduction goals. We will also continue to reduce waste; save energy; manage chemicals safely, securely and sustainably; and protect food and water security. For example, part of Kuraray‘s electricity supply is being provided by renewable sourcing. • Product: Innovating sustainable products for a circular economy, aiming for 60% revenue from eco-friendly products by 2026. • People: Cultivating an inclusive workplace where people thrive and materials are sourced responsibly, giving back to communities along the way. *SBT (Science Based Targets): Voluntary targets set by business corporations with regards to GHG emission reductions in a manner consistent with the levels required by the Paris Agreement. The SBT certification ensures that the Company’s targets are scientifically based and aligned with the goals of the Paris Agreement.
For people and the planet – to achieve what no one else can.
Our commitment to sustainability — 19
18 — Our commitment to sustainability
OPERATION CLEAN SWEEP Committed to preventing plastic pellet spills since 2019, earning OCS certification in 2025.
INTERMODAL TRANSPORT Reduced CO₂ emissions by 55% using rail and ship transport, improving sustainability and efficiency (combining a global presence with local supply).
EVAL Europe N.V.’s sustainable initiatives When it comes to sustainability, actions that appear small at first sight can have a big impact. At EVAL Europe N.V., we invest in making our supply chain greener. There are six initiatives that we have implemented recently to protect the environment and shape our work sustainably.
REUSABLE PALLETS (PRS) Employing PRS since 2020 to avoid waste; saving one tree for every seven pallets reused.
RENEWABLE ENERGY We are investing in electricity from renewable sources.
RECYCLED FOIL WRAPPING Utilising foil with 30% post-consumer recycled content for sustainable packaging.
MANUFACTURING OPTIMISATION Achieved a 30% reduction in energy use, with ongoing improvements to meet climate neutrality goals.
Our commitment to sustainability — 21
20 — Our commitment to sustainability
Inspired by our initiatives? Get in touch so we can explore how these practices can transform your packaging strategies. Together, we can craft solutions that align with sustainability goals and drive meaningful change. Let’s lead the way in reshaping the future of packaging. 6 Working towards a sustainable future together
NOTICE
The information, specifications, procedures, methods and recommendations herein are presented in good faith, are believed to be accurate and reliable, but may well be incomplete and/or not applicable to all conditions or situations that may exist or occur. No representation, guarantee or warranty is made as to the completeness of said information, specifications, procedures, methods and recommendations or that the application or use of any of the same will avoid hazards, accidents, losses, damages or injury of any kind to persons or property or that the same will not infringe patents of others or give desired results. Readers are cautioned to satisfy themselves as to the suitability of said information, specifications, procedures, methods and recommendations for the purpose intended prior to use. EVAL 03/072025/V1 Copyright Kuraray Co., Ltd. Photos used in this brochure are representative of potential product applications only.
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Working towards a sustainable future together — 23
22 — Working towards a sustainable future together
EVAL Europe N.V. Haven 1053 - Nieuwe Weg 1, Bus 10 2070 Beveren-Kruibeke-Zwijndrecht (Antwerp) Belgium P +32 3 250 97 33 eval.eu@kuraray.com
KURARAY AMERICA, INC. EVAL BUSINESS UNIT 3700 Bay Area Blvd., Ste 680 Houston, Texas 77058 USA
P + 1 800 423 9762 eval.us@kuraray.com
KURARAY ASIA PACIFIC PTE. LTD. 1 North Buona Vista Link, #12-10/11 Elementum,
Singapore 139691 P +65 6337 4123 eval.jp@kuraray.com
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