Eurocast, a producer of multilayer flexible films, is implementing a multi-year R&D project focused on the development, industrial deployment and internationalisation of an innovative cast polypropylene film under the name Castfol RPP with a high share of secondary raw material. The project also includes the implementation of a predictive maintenance system in APET film production, in line with Industry 4.0 principles. The undertaking is co-financed by the European Union under a programme managed by the Polish Agency for Enterprise Development. The key objective of the project is to obtain a film structure designed for food contact, containing in total up to 60% recycled polypropylene regranulate, while maintaining performance parameters comparable to materials produced from virgin feedstock. In addition, it is planned to reduce the film thickness from 40 to 30 µm, which is expected to reduce raw material consumption and packaging waste throughout the product life cycle.
Project assumptions for Castfol RPP and work schedule
The project covers the development, implementation and internationalisation of the Castfol RPP film, as well as the deployment of digital tools for predictive maintenance in APET film production. The aim is to increase Eurocast's competitiveness by developing new production technologies and implementing advanced ICT solutions in line with the Industry 4.0 concept.
The work has been divided into four modules:
- research and development (R&D),
- internationalisation,
- industrial implementation,
- digitalisation.
The project is scheduled for the years 2025–2030. The key element is the development of a multilayer cast polypropylene film with a high share of recycled PP regranulate, dedicated primarily to packaging applications for food contact.
Multilayer cast film with a high recyclate content
The planned Castfol RPP film is to be a structure with at least five layers, with individual layers providing specific functions such as mechanical properties, sealability or the share of secondary raw material. The main challenge is the high, up to around 60%, content of polypropylene regranulate while maintaining application properties comparable to those of material made from virgin feedstock.
As emphasised by Damian Dziadowiec, PhD Eng, head of the R&D department at Eurocast: "Castfol RPP is a cast film that will contain in its composition up to around 60% polypropylene regranulate from recycling. Our goal is to introduce recycled material into food-contact packaging without deteriorating key performance parameters such as mechanical properties, sealability or transparency. At the same time, we are working to ensure that the new material maintains high optical quality and process stability, which is one of the biggest technological challenges when using recycled feedstock. It is also crucial for us to reduce raw material consumption by decreasing film thickness, which will increase the material efficiency of packaging."
Damian Dziadowiec, PhD Eng, head of the R&D department at Eurocast
Optical and mechanical quality of film with recyclate
One of the main technological challenges in the use of recycled PP for film production is maintaining optical and mechanical properties at a level acceptable for packaging applications, in particular in the food segment. Recycled materials often lead to deterioration of transparency, gloss and strength parameters.
Within the project, advanced work is being carried out on:
- developing a regranulation process for PP waste that will allow its safe reuse in food-contact packaging,
- preparing formulations for the individual film layers,
- developing a model technology for the production of Castfol RPP film.
The target film is intended to balance a high proportion of recyclate with the requirements for optical quality, such as adequate transparency and gloss, and with the stability of the processing conditions.
Piotr Szymczak, PhD Eng, chief operating officer at Eurocast, points to the importance of the planned share of secondary raw material: "Our goal is to develop a material which, with a high recyclate content, will retain properties no worse than currently used films made from virgin raw material. Achieving around 60% recycled content will be a very significant step for the packaging industry. Equally important for us is maintaining high optical quality of the film, including appropriate transparency and gloss, which are crucial for packaging producers and the food sector. If we manage to combine these parameters with a high share of secondary raw material, it will be a solution that can genuinely change the way polypropylene packaging is designed in the future."
Piotr Szymczak, PhD Eng, chief operating officer at Eurocast
Film thickness reduction and material efficiency
An integral part of the project is the reduction of film thickness from 40 to 30 µm while maintaining the same physical and mechanical properties. This means that, for the same packaging area, it will be possible to use a smaller amount of material, which directly translates into lower raw material consumption and a reduction in packaging waste.
According to the project assumptions, reducing film thickness is expected to increase the material efficiency of packaging by up to around 33%. In practice, this will result in lighter packaging, a lower material footprint and potential benefits in logistics and waste management.
Stages of R&D work and film prototypes
The R&D module has been scheduled for 36 months and comprises three main stages. In the first stage, a regranulation process for PP waste will be developed, tailored to the requirements for reusing the material in food-contact packaging. The next stage covers the development of formulations for the individual film layers, taking into account mechanical performance, sealability and the level of recyclate content in the structure.
In the subsequent stage, a model technology for the production of Castfol RPP film will be developed, including processing parameters for cast film extrusion and conditions ensuring product quality stability. The final result of the R&D work is to be two film prototypes:
- Castfol RPP Seal with sealing functionality,
- Castfol RPP Seal AF with sealing functionality and an anti-fog coating to limit fogging.
After completion of the R&D phase, activities related to industrial implementation are planned, including the preparation of technical documentation, product certification, patent application and the purchase of a new production line and associated infrastructure.
Digitalisation of APET film production and predictive maintenance
The digitalisation module, scheduled to start in 2027, focuses on implementing a predictive maintenance system in APET film production. The system is to use process data analysis and machine learning algorithms to predict potential failures and minimise unplanned production line downtime.
It is assumed that these solutions will reduce failure rates, shorten maintenance response times and decrease the amount of production waste generated as a result of process disruptions. The implementation of such tools is in line with the broader trend of digitalising industrial processes and deploying the Industry 4.0 concept in the plastic film and packaging production sector.
Internationalisation of the technology and target groups
The project also has a clear export dimension. As part of the internationalisation module, the Castfol RPP technology is to be promoted on foreign markets, in particular at trade fairs and conference events dedicated to packaging and plastics.
The direct recipients of the developed film are to be converters and packaging producers, companies from the food sector, as well as manufacturers of packaging for other markets using polypropylene films. The technology is aimed at entities seeking solutions that combine a high share of secondary raw materials with the quality requirements typical of food packaging.
Sustainable development and potential impact on the packaging market
The introduction of Castfol RPP film may be significant for transforming the polypropylene packaging market towards greater use of secondary raw materials. Thanks to the high recyclate content, food producers and retail chains will be able to use packaging that meets the increasing environmental and regulatory requirements of the European Union while retaining the required performance characteristics.
Krzysztof Wiśniewski, president of the management board of Eurocast, indicates the potential business and environmental effects of the project: "The implementation of the project will allow us to diversify production by introducing a new product, increase the company's revenues and strengthen our competitiveness on international markets. At the same time, we are developing technologies that are in line with the direction of more sustainable packaging production. We are convinced that the project will also contribute to a broader use of secondary raw materials in the packaging industry. The new technology will enable packaging manufacturers and companies in the food sector to bring more environmentally oriented solutions to the market without compromising on quality and functionality. In the longer term, this may also change the way plastic packaging is perceived by consumers and contribute to an increase in polypropylene recycling levels in Europe."
Krzysztof Wiśniewski, president of the management board of Eurocast
The implementation of the Castfol RPP project combines the development of new packaging materials with the deployment of digital tools in maintenance, aligning with broader trends in technological and environmental transformation in the plastics and packaging industry.
