In recent years, polyethylene terephthalate (PET) foils have become the ideal choice for food packaging because of their excellent barrier properties, sustainability, and versatility. PET foils, often made from recycled materials such as PET bottle waste, are increasingly replacing traditional packaging materials. This change is a result of the demand for environmentally friendly and economical packaging that also ensures food safety and quality. BG Plast has become a benchmark for these demands, thanks to our innovative PET foil extrusion lines designed to optimize both performance and safety.
BG Plast’s technology for PET thermoforming foil extrusion is the combination of efficiency and sustainability
The advantages of PET foils in food packaging
PET foil offers several advantages that make it ideal for food packaging. It provides an effective barrier against oxygen and moisture, preserving the freshness and durability of packaged food products. Its excellent mechanical strength ensures its durability, making it resistant to tears, punctures and impacts during transport and handling. In addition, PET foils are lightweight, helping to reduce shipping costs and carbon dioxide emissions.
In addition, PET is a recyclable material, in line with the global trend favoring sustainable packaging solutions. With recycled PET (rPET) in the production process, manufacturing companies can reduce plastic waste and contribute to a circular economy.
Sustainability: the use of recycled PET in the production of thermoforming foils
One of the most significant developments in the production of PET foils is the increasing use of recycled PET waste from post-consumer bottles. A practice that not only reduces environmental impact but also offers cost savings. The challenge is to process these recycled materials without compromising the quality of the final product.
This is why BG Plast has developed advanced extrusion technologies that incorporate high-performance dosing systems capable of ensuring that recycled PET flakes are processed with minimal loss of inherent viscosity (IV), a critical factor in maintaining the material’s mechanical properties and performance.
Multilayer coextrusion to improve performance
For food packaging, PET foils must meet strict safety standards, especially when in direct contact with food. To achieve this goal, BG Plast’s PET extrusion lines use multilayer coextrusion technology. This is a process that allows manufacturers to make A-B-A structures, where the inner layers (B) can be made from recycled PET, while the outer layers (A) are made from virgin PET. This ensures that only virgin, safe materials come into contact with food, while the majority of the foil is composed of recycled content.
The multilayer approach balances performance, cost, and safety, making it a highly effective solution for food packaging applications. The outer layers provide the necessary protective barrier, while the recycled inner layer reduces material costs and promotes sustainability.
Extruded PET foils are safe for food contact due to the combination of recycled and virgin PET
Moisture control and inherent viscosity: key factors in PET processing
A critical factor in the production of high-quality PET foils is moisture control. PET is hygroscopic, that is, it absorbs moisture from the air, a characteristic that can lead to degradation of the material during the extrusion process. Excess moisture can cause a reduction in the intrinsic viscosity (IV) of PET, resulting in a less durable and lower quality foil.
To eliminate this problem, we have developed PET extrusion lines equipped with advanced degassing systems that remove moisture from the material before it enters the extruder. This ensures that recycled PET retains its inherent viscosity, enabling the production of strong, durable foils that can withstand the demands of food packaging.
More profitable production with single-screw extruders
To further improve the efficiency of PET foil production, BG Plast offers single-screw extruders equipped with multiple dosing units. These systems can handle a mixture of virgin material, masterbatch and recycled PET flakes. The single-screw extruder design allows for a streamlined production process, reducing the need for expensive drying systems. The result is an economical solution that provides high-quality PET foils.
For high-volume production, BG Plast also offers twin-screw extruders, which provide even greater efficiency and flexibility. These systems can process a variety of raw materials, including recycled PET, without the need for pre-drying, further reducing operating costs.
Food safety and regulatory compliance in PET packaging
In food packaging, safety is paramount. PET foils used in food packaging must comply with strict regulatory standards to avoid posing a potential health risk to consumers. BG Plast’s extrusion technology is designed to produce PET foils that comply with food safety regulations, including those regulating the use of recycled materials in contact with food.
The multilayer co-extrusion technology used in our extrusion machinery ensures that virgin PET is used for the layers in direct contact with food, minimizing potential risks from recycled materials. In addition, the extrusion lines are equipped with high-performance vacuum pumps that remove contaminants and ensure that the final product meets required safety standards.
Applications of PET foils in the food industry
PET foils are used in a wide range of food packaging applications, including thermoformed containers, blister packs, and lidding films. The foils are ideal for packaging perishable foods such as fruits, vegetables, meat and dairy products, as they can provide an excellent barrier against moisture and oxygen.
The use of PET foil is also growing in the ready-to-eat and convenience food markets, where packaging must not only protect the product but also offer features such as resealability and microwaveability. PET foils meet these needs while maintaining the highest food safety standards.
PET foils are ideal for the production of various types of food packaging
Efficiency and sustainability in PET food packaging with BG Plast
As demand for sustainable packaging solutions continues to grow, PET foils are set to play an increasingly important role in the food packaging industry. With their excellent performance, recyclability and safety characteristics, PET foils offer an economical and environmentally friendly alternative to traditional packaging materials.
BG Plast’s advanced PET foil extrusion lines provide manufacturers with the technology needed to produce high-quality, sustainable packaging solutions that meet the demands of consumers and regulators. A balance of performance, cost optimization and safety we ensure to help drive the future of food packaging toward a more sustainable and efficient model.
What is your project? Ask BG Plast for the solution to maximize the production of your PET packaging.