High-performance recycled linear low density polyethylene grade containing 85% post-consumer recycled content is produced at Ecoplast, a member of the Borealis Group, using an INTAREMA extrusion system.
Creating flexible packaging with high recycled content is a significant technical challenge – but Borealis has succeeded with Borcycle™ CWT120CL. Designed for demanding non-food flexible packaging applications, this recycled linear low density polyethylene (rLLDPE) contains an impressive 85% post-consumer recycled (PCR) content.
The grade is part of Borealis’ Borcycle™ M portfolio – a range of mechanically recycled polyolefins made from post-consumer waste. These materials combine a reduced carbon footprint with reliable performance, making them suitable replacements for virgin polyolefins in many applications.
“This is how we bring our We4Customers strategy to life – with high-performance materials that meet our customers’ most demanding requirements. Borcycle CWT120CL represents a significant technical achievement, made possible by our expertise, Ecoplast’s capabilities, and EREMA’s ad-vanced technology.”
Peter Voortmans, Borealis Vice President Marketing Consumer Products
High-purity recyclates that deliver stretch, strength, and sustainability
Borcycle CWT120CL was developed in collaboration with Ecoplast, a member of the Borealis Group. Production takes place at Ecoplast’s site in Wildon, Austria, using an INTAREMA® extrusion system.
The setup combines EREMA’s Preconditioning Unit (PCU) with patented Counter Current technology, patented laser filter and double filtration technology, as well as double degassing to effectively remove impurities. The resulting pellets meet the high purity and consistency requirements needed to produce advanced rLLDPE grades such as Borcycle CWT120CL.
With ecoSAVE® technology, energy consumption is up to 12% lower, further reducing environmental impact.
Supporting the path toward PPWR compliance
Borcycle CWT120CL helps manufacturers improve the sustainability of products such as stretch film, stretch hoods, and other protective and agricultural films. It was developed as a direct response to the need for high-performance recycled content solutions that support ambitious sustainability targets. That includes the EU’s Packaging and Packaging Waste Regulation (PPWR), which introduces mandatory recycled content levels for plastic packaging from 2030.
“At EREMA, our mission is to make plastics recycling as innovative and efficient as possible. We’re proud that our technology has enabled this step toward circularity in demanding flexible packaging applications.”
Clemens Kitzberger, Business Development Manager Post Consumer Recycling at the EREMA Group.
Dishwasher tablet pouch: This pouch is made from 120 µm PE blown film containing 40% Borcycle™ CWT100VL. It is a fully recyclable PE monomaterial without lamination, reduced COVs and CO₂ emissions. It has been produced in cooperation with Comexi, Asahi Kasei, Elplast, HB Fuller, Messpack and Huber Group.
Toilet paper packaging: This flexible packaging for paper products is produced with over 80% Borcycle™ CWT100VL post-consumer recycled material. Developed in collaboration with Rani Plast, the film ensures an optimal balance between high circularity and appearance. The rLLDPE is combined with transparent, high-purity polyethylene to maximise PCR content without increasing material thickness.
