PCR-based flexible packaging materials with high recycled content have been considered difficult substrates for high-quality print reproduction. Especially in applications using more than 90% post-consumer recycled (PCR) content, visible haze and material inconsistencies often limited the achievable print quality.

As a result, many of these materials have traditionally been used for relatively simple applications such as courier envelopes, transport packaging or duty-free bags with basic solid areas and line graphics rather than demanding image-driven designs.

With the introduction of the PPWR, this challenge will move much more into the center of attention, as the use of 30% recycled content in packaging placed on the market is expected to become mandatory from 2030 onwards, with increasing recycled content targets in the years ahead.

During the recent Next-Generation Sustainable Flexo Symposium, print results on transparent PCR material demonstrated how rapidly flexographic printing technology is evolving. Despite the visible haziness of the substrate itself, which contained more than 90% PE PCR, the printed image quality achieved during the tests showed that high-quality graphics on challenging PCR films may now be more achievable than many in the industry previously expected.

The results highlighted how advances in plate technology, screening, press stability and workflow optimization can help overcome limitations that were historically associated with recycled flexible packaging materials.

Brand owners increasingly want packaging that supports both sustainability targets and strong visual brand presentation. However, this has often created a difficult compromise: higher recycled content can support environmental goals but may negatively affect the appearance of the final printed packaging.

The ability to achieve improved print quality on highly recycled substrates could help expand the use of PCR materials into new packaging segments.

Instead of being limited mainly to simple industrial or transport applications, high-PCR content flexible packaging may increasingly become viable for more demanding consumer packaging designs that require stronger visual impact and more detailed graphics.

One of the key takeaways from the symposium was that these developments are not driven by a single technology alone.

Progress depends on close collaboration across the entire flexographic ecosystem, including plate technology, screening and imaging, inks, tapes, substrates, press technology and process automation.

The latest print results shown during the symposium suggest that sustainable packaging no longer has to automatically mean compromised print quality, and that flexo continues to play an important role in enabling this transition.