Frequently asked questions

Flexible packaging, mono-material films, recyclability, PPWR, LCA data. Quick answers to the questions we hear most often from customers, brand owners and stakeholders.

The company

Who is Poplast and what does it do?

Poplast Group is an Italian converter of flexible packaging, in business since 1975. From two production facilities — Castel San Giovanni (Piacenza) and Lamporecchio (Pistoia) — we develop and produce printed, laminated and slit films for food, pharmaceutical and industrial packaging, supplying brand owners and manufacturers in Italy and over 30 countries worldwide.

Where are Poplast's production facilities?

Two production facilities in Italy: the main plant in Castel San Giovanni (Piacenza) and the second plant in Lamporecchio (Pistoia). Together, more than 37,000 sqm of production area and 15,000 sqm of warehousing, with 7 flexo lines, 11 laminators and 16 slitter rewinders.

Does Poplast serve export markets?

Yes. Poplast supplies customers in Italy and across the main global markets, with a consolidated presence built through dedicated distribution partners.

Which certifications does Poplast hold?

Poplast is certified to ISO 9001 (since 1995), ISO 14001 (since 2004), BRCGS Packaging (since 2010), FSC® (since 2017), ISCC PLUS and Kosher. We are also Ambassador of the Fondazione Carta Etica del Packaging. Cyclos-HTP and Recyclass recyclability certifications are available on individual mono-material items.

Products & materials

What is flexible packaging?

Flexible packaging is a thin, formable packaging material — typically a plastic film, a laminate or a multi-layer structure — that conforms to the shape of the product it contains. Compared with rigid packaging, weight and transport footprint are considerably lower.

Which materials does Poplast work with?

Poplast mainly works with polypropylene (PP), polyethylene (PE), polyester (PET) and polyamide, in both mono-material and multi-layer structures. We also offer solutions with post-consumer recycled content (up to 60% PCR on non-food applications) and EN 13432-certified compostable films.

What are mono-material films?

Mono-material films are structures built on a single base polymer (typically PP or PE), designed to be collected and recycled through existing end-of-life streams. They replace traditional laminates that combine different materials which are hard to separate — for instance PET/aluminium/PE.

What is the difference between mono-material and multi-layer films?

Multi-layer laminates couple different polymers to optimise barrier and performance, but they are hard to recycle because the materials cannot be separated in standard streams. Mono-material films use a single base polymer and reach comparable performance while remaining recyclable.

A further advantage of mono-material PP is a wider sealing window: packaging lines can run at lower temperatures (down to -30°C compared with aluminium structures), which translates into energy savings.

Does Poplast produce compostable packaging?

Yes. Our bio-based range is derived at least 85% from renewable feedstocks (cellulose residues and sugarcane) and is certified compostable to EN 13432 and EN 14995 (TÜV Austria, DIN CERTCO). It is intended for industrial composting.

Can Poplast packaging be customised?

Yes. Our R&D department and pre-printing office develop tailor-made solutions on format, structure, barrier and print. Customisation starts from an analysis of product requirements, packaging line and distribution channel specifications.

Can Poplast match the barrier of a traditional laminate with a mono-material?

In most applications, yes. Mono-material PP structures with a metallised layer reach oxygen and water-vapour barriers compatible with a 24-month shelf life (as verified for coffee in the CIPACK LCA study). On very-high-barrier applications, each case has to be assessed on its own merits.

Technologies

What is the difference between flexographic and rotogravure printing?

Flexography uses photopolymer plates and water- or solvent-based inks: it suits small to medium print runs and frequent artwork changes. Rotogravure uses engraved cylinders and delivers higher definition and consistency on long runs and complex graphics.

The choice depends on volume, artwork complexity, number of colours and how often versions change.

What is solvent-based and solventless lamination?

Lamination bonds two or more films through an adhesive. The solvent-based process uses solvent-diluted adhesives, with the solvent recovered in a closed loop through an RTO with distillation. The solventless process uses two-component solvent-free adhesives, with lower emissions and energy consumption.

Does Poplast work with metallised films?

Yes. Poplast uses metallised films (typically metallised PP-HB) as a barrier layer within mono-material laminates. Metallisation replaces aluminium foil in many applications, reducing overall thickness while keeping the film recyclable.

Sustainability & recyclability

Are Poplast packaging solutions recyclable?

The mono-material PP and PE structures developed by Poplast are certified as recyclable by the independent bodies Cyclos-HTP and Recyclass (Class B, recyclability above 94%).

What are Cyclos and Recyclass certifications?

They are two of the leading European bodies that assess the recyclability of plastic packaging against objective technical criteria. Cyclos-HTP (Germany) issues single-item certificates with quantified recyclability figures. Recyclass classifies packaging from A (full recyclability in a closed-loop system) to F (not recyclable) on the basis of design.

What is the difference between Design for Recycling and actual recyclability?

Design for Recycling refers to designing the film according to principles that make recycling possible. Actual recyclability depends on context: separate collection, sorting, and the recycling infrastructure available locally. A well-designed pack is necessary but not sufficient.

Has Poplast carried out LCA studies on its products?

Yes. Poplast has carried out a peer-reviewed LCA study in collaboration with CIPACK – University of Parma, published in Environmental Impact Assessment Review (Elsevier): DOI: 10.1016/j.eiar.2025.108321. The study compares mono-material films with traditional multi-layer structures for coffee, dried fruit and cheese packaging, following ISO 14040/14044 standards and the EF 3.1 methodology.

Read more on the LCA study

What CO₂ reductions come out of the LCA study?

Compared with traditional multi-layer structures, Poplast mono-material solutions cut emissions by up to 44% on coffee, up to 25% on dried fruit and up to 11% on cheese (Climate Change category, EF 3.1 method).

The study covers all 13 impact categories and transparently reports the cases where mono-material does not show a systematic advantage — for instance on some fossil-resource-use categories within the cheese structure.

Does Poplast use recycled materials (PCR)?

Yes. On non-food applications, Poplast supplies polyethylene structures with post-consumer recycled content up to 60%. On food applications, PCR use is constrained by the limits set by EU food-contact legislation; the offer develops in step with the evolving regulatory framework.

Is Poplast ISCC PLUS certified?

Yes, since 2024. ISCC PLUS certifies traceability of bio-based and recycled feedstocks along the value chain, under a mass balance approach. It is relevant for customers developing products with reduced fossil content.

PPWR & regulations

What is the PPWR Regulation?

It is EU Regulation 2025/40 (Packaging and Packaging Waste Regulation), which replaces the previous packaging directive. It introduces obligations on recyclability, recycled content, minimisation, substances of concern and end-of-life management, applying to all packaging placed on the EU market.

When does the PPWR apply?

The PPWR applies from 12 August 2026, with requirements phasing in over time. Many technical details are still being defined through delegated acts and EU Commission guidelines.

Do Poplast materials meet PPWR limits on PFAS and heavy metals?

Yes. Poplast structures meet the limits set out in Article 5 of the PPWR for PFAS and heavy metals in food-contact materials. PFAS are not intentionally added to our films.

Does the PPWR force converters to use a single material?

No. The PPWR sets recyclability and performance requirements but does not mandate a specific technology. Material choice still depends on required shelf life, product type, packaging line and distribution channel.

Will existing packaging need to be redesigned for the PPWR?

In most cases yes, at least partly. The extent of the changes varies by application: some multi-layer structures will need to be replaced by equivalent mono-materials; others will only need label or composition updates. Assessment has to be done case by case, at SKU level.

Do mono-material films run on existing packaging lines?

In many cases yes, but compatibility has to be verified on each line. Mono-material PP structures have a wider sealing window (down to -30°C compared with aluminium laminates) and allow thickness reduction; line trials remain part of the development path.

What does being "PPWR ready" mean?

It means having aligned the product range with Design for Recycling principles, having certified LCA and recyclability data available, and being able to support the customer through the transition. It is not equivalent to full formal compliance, since the regulatory framework continues to evolve through delegated acts and guidelines.

What does the PPWR mean for brand owners?

Packaging decisions will have to balance product performance, operational requirements and evolving regulatory obligations more tightly: binding recycled-content targets for plastics from 2030, recyclability requirements, packaging minimisation, harmonised labelling. Reliable data, testing and case-by-case assessment on each reference become essential.

Working together

How do you start a project with Poplast?

The first step is a commercial contact to share the brief: product to pack, format, expected shelf life, packaging line and distribution channel. R&D assesses the best structure, pre-printing handles the artwork, and production starts once technical validation is complete.

Does Poplast provide tailored LCA and carbon footprint data?

Yes, on request and based on the agreed scope. Primary data on films come from actual production; calculation methods follow ISO 14040/14044 standards and the relevant sector PCRs. The CIPACK research group at the University of Parma is our reference scientific partner.

Does Poplast handle prototyping and print trials?

Yes. Our pre-printing office manages colour proofs and chromalines in-house; flexo and rotogravure press trials are scheduled once the artwork file and the technical structure have been signed off.

Can Poplast handle small print runs?

Flexography is the technology best suited to small to medium print runs and frequent artwork changes. On long runs or highly complex graphics, rotogravure offers technical and economic advantages. The assessment happens at the commercial stage.

Didn’t find what you were looking for?

Our sales and R&D team is available to review technical, regulatory and sustainability aspects of your project.

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