Films
HyperBarrier® Film
A high-performance monomaterial PE barrier film that delivers up to 300× better oxygen barrier while remaining fully recyclable—replacing complex multi-layer plastic structures without performance trade-offs.
Oxygen Barrier
improvement over LDPE film
Moisture Barrier
improvement over LDPE film
PE Recyclable
monomaterial structure
The Challenge: High-Barrier Packaging Meets Recyclability
For decades, the packaging industry has faced a fundamental trade-off: delivering high oxygen and moisture barrier for sensitive products meant relying on multilayer laminates, metallized films, or polar barrier polymers like EVOH and PVOH. These solutions achieve excellent barrier in laboratory conditions, but they suffer from severe limitations in real-world applications.
Conventional high-barrier films collapse under humidity, become brittle at folds and creases, and are incompatible with PE recycling streams. Meanwhile, neat low-density polyethylene (LDPE)—which is robust and fully recyclable—offers minimal gas barrier, making it unsuitable for oxygen-sensitive products. This gap has left brands and converters with an impossible choice: compromise on barrier performance or abandon recyclability.
HyperBarrier Film directly addresses this gap. By harnessing the barrier potential of polyethylene through engineered nanoclay morphology, we deliver high, humidity-stable barrier in a monomaterial PE structure designed for PE-stream recyclability—without performance trade-offs or new capital equipment.
How It Works: Nanoclay Barrier Technology
HyperBarrier Film is a polyolefin nanocomposite that unlocks the barrier potential of polyethylene through a tailored nanoclay morphology. The innovation uses organically modified montmorillonite nanoclays that are highly exfoliated, aligned, and dispersed within the PE matrix, creating a tortuous diffusion pathway for gases.
In this design, tortuosity rather than polymer polarity is the dominant barrier mechanism. The aligned mineral network effectively becomes the barrier layer inside the monomaterial film, delivering oxygen transmission rates of 10–25 ccm/day at 1 mil—an improvement of up to 300× over LDPE.
Crucially, this barrier performance is maintained under real-world stress. At 90% relative humidity, HyperBarrier Film delivers moisture vapor transmission rates of 5–8 g/m²·day and retains its oxygen barrier, whereas EVOH and PVOH show severe moisture-induced degradation. Mechanical durability testing shows that HyperBarrier Film maintains OTR values of 10–25 ccm/day after folding and creasing, while brittle high-barrier alternatives are prone to cracking and barrier loss.
The HyperBarrier Film Advantage
Six core capabilities that transform flexible packaging sustainability.
Superior Oxygen Barrier
HyperBarrier Film delivers up to 300× better oxygen barrier performance compared to conventional low-density polyethylene film, with oxygen transmission rates of 10–25 ccm/day at 1 mil.
Monomaterial PE Film
A single-layer polyethylene nanocomposite that eliminates the need for complex multi-layer film laminations, metallized films, or polar barrier polymers like EVOH and PVOH.
Fully Recyclable
As a monomaterial polyethylene film, HyperBarrier Film is fully compatible with existing PE recycling streams and designed to meet design-for-recycling and EPR framework requirements.
Humidity-Stable Performance
Unlike conventional high-barrier alternatives, HyperBarrier Film maintains its oxygen barrier and mechanical durability at 90% relative humidity, with barrier retained even after creasing.
Drop-In Integration
Runs on standard blown film, cast film, and extrusion coating lines without metallization, coatings, specialty tie layers, or adhesive lamination—converters can upgrade performance using existing assets.
Extended Shelf Life & Grease Proof
Superior protection against oxygen, moisture, and oils supports product quality and integrity while extending shelf life for oxygen- and moisture-sensitive products in demanding supply chains.
Environmental Impact
HyperBarrier Film addresses a core sustainability challenge in flexible packaging: delivering high barrier in structures that remain recyclable and compatible with emerging EPR regulations.
Eliminates Non-Recyclable Barriers
By replacing metallized layers, PVDC, PVOH, and EVOH-based multilayers with a single monomaterial PE film, HyperBarrier Film removes incompatible barrier components that are problematic under EPR schemes and recycling infrastructure.
Simplifies Material Complexity
Reduces the share of high-barrier packs treated as residual waste and lowers exposure to future eco modulation penalties on non-recyclable formats. Simplified structures also improve yields and reduce product waste from delamination.
Supports Circular Design
Enables high-barrier films to follow the same recycling pathways, design rules, and infrastructure as mainstream polyethylene, supporting portfolio simplification and improved recyclability scores for converters, retailers, and brands.
The Circular Advantage: By enabling high oxygen and moisture barrier in fully polyethylene films that avoid EVOH, metallized PET, PVDC, and other incompatible layers, HyperBarrier Film helps converters and brands move high-barrier applications into recyclable PE formats while meeting tightening recyclability goals.
This shift toward monomaterial recyclability does not come at the expense of product protection. HyperBarrier Film achieves superior barrier performance while eliminating metallization steps, solvent or water-based barrier coatings, and many adhesive lamination operations—reducing process complexity, energy use, and the number of materials in a pack.
Ideal Applications
HyperBarrier Film is suited for oxygen- and moisture-sensitive products in demanding supply chains, including:
Dry foods and snacks
Coffee and tea
Nuts and seeds
Spices and seasonings
Pet food
Pharmaceutical and nutraceutical products
High-humidity or tropical supply chains
Export and long-shelf-life applications
Ready to Explore HyperBarrier Film?
Contact us to learn how HyperBarrier Film can replace multi-layer plastic structures in your flexible packaging while ensuring recyclability and meeting your sustainability goals.
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