Duo Packaging develops new advanced material for next-gen flexible packaging

Duo Packaging, a Manchester-based specialist in flexible plastics, has developed a graphene-enhanced flexible packaging film, 2DPETM, aimed at the retail and e-commerce sectors. This innovation, in collaboration with the University of Manchester's Graphene Engineering Innovation Centre (GEIC), aims to increase the use of recycled content in flexible packaging while reducing material consumption.

The new material maintains tensile strength and tear properties while improving processing and energy efficiency during manufacturing. Industrial trials with GEIC and live shopping retailer QVC demonstrated that the film enhances material strength by up to 35% and increases recycled content in packaging from 45% to 60%.

QVC has adopted 2DPETM at its UK fulfillment center in Liverpool, replacing standard autobagging film. This transition is projected to save approximately 50 tonnes of virgin plastic and 148,000 tonnes of carbon emissions annually. Additionally, the 5% weight reduction could save QVC around £21,150 in packaging Extended Producer Responsibility (EPR) fees each year.

Initially, 2DPETM is being used to produce e-commerce mailing bags and autobagging film, commonly used by retailers for packaging various products such as clothing, cosmetics, homewares, and toys. With an estimated 941 million plastic mailing bags delivered to UK shoppers annually, the sustainability benefits of 2DPETM could be substantial.

Zoe Brimelow, co-owner and brand director at Duo, emphasized the need for commercially and operationally viable solutions to improve packaging sustainability. She noted that graphene was key to addressing challenges faced by retailers, including cost pressures and regulatory demands, without compromising performance.

Mark Dickie, applications manager at GEIC, highlighted that Duo's innovation exemplifies how graphene's properties can significantly enhance everyday products, supporting the transition to a circular economy. Dale Brimelow, Duo co-owner and operations director, pointed out the impact of the EU's Packaging and Packaging Waste Regulation on the industry, driving changes in packaging standards beyond the EU.