Testing a coated PE-based mono-material for food packaging applications: an in-depth performance comparison with conventional multi-layer configurations

A polyethylene (PE)-based mono-material was considered as an alternative to multi-layer configurations widely used within food packaging sector. An in-depth characterization was performed and several properties (optical, gas/vapor-barrier, and mechanical) tested for the mono-material and selected multi-layer films. The mono-material showed an outstanding performance concerning oxygen (0.18 ± 0.01 ∙ 10−6 mol m−2 s−1) and water vapor (2.84 ± 0.22 ∙ 10−5 g m−2 s−1) barrier properties, which were ascribed to a thin oxygen barrier coating and the inherent PE hydrophobicity, respectively. The coating also provided excellent UV-C shielding ability, tensile/puncture resistance, and friction properties comparable to those of multi-layer systems. The environmental performance of the materials assessed via LCA showed that the mono-material represented the configuration with the lowest environmental profile. This preliminary work highlighted the potential of PE-based mono-materials functionalized via coating technology as an alternative to multi-layer configurations, thus embracing the increasing demand for more environmentally sustainable solutions (100 % recyclable).