CIRFLEX: Closing the gap for flexible packaging

Prototypes, better recyclates, and design guidelines

CIFLEX develops flexible packaging prototypes designed to meet or exceed PPWR requirements. The work includes increasing the recycled content, improving design-for-recycling, and developing viable approaches for reuse applications such as e-commerce packaging.

The project focuses on improving the quality and the processability of recycled polyolefins by the strategic use of additives to achieve an optimal performance in the packaging containing recycled content. Additionally, a model to predict the sealing behavior of polyolefins packaging is developed using data from the sealing measurements of commercial packaging films.

The knowledge generated is consolidated into design guidelines (for design from recycling and design for reuse) to help the wider plastics packaging industry meet circularity targets with strong economic performance.

Reduce risk for industry

Pilot tests demonstrated the reusability of flexible e-commerce packaging over several reuse cycles without visible damage, helping to build confidence for real-world roll-out. In parallel, films and products with high levels of post-consumer recycled content were successfully produced and tested at industrial scale, an important step toward market-ready applications.

The industrial partners supported TNO-BMC in developing the predictive sealing model for polyolefins films (PE, PP, and blends, including virgin and recycled materials), by providing commercial packaging films for testing, which generated key input data alongside other data sources.

From project results to scaled implementation

After CIFLEX, the next step is scaling proven concepts into repeatable, industrial-grade solutions: validated recyclate supply chains, packaging formats that deliver performance with recycled content, and reuse models supported by reverse logistics.

This requires continued collaboration across the chain from packaging producers, recyclers, logistics providers to brand owners so that circular flexible packaging becomes the default rather than the exception.

TNO is looking to connect with organisations that want to pilot, validate, or scale circular flexible packaging solutions like recycled-content designs, design guidelines, and reuse models for e-commerce.