Dow, Macchi and ITP present new mono-polyethylene pouch prototype with more than 50% advanced recycled content at K 2025

Three key players in the packaging supply chain – Dow,
Macchi, and ITP – have joined forces to develop a circular solution for flexible packaging: a mono-polyethylene (mono-PE) pouch designed for recyclability, containing over 50% recycled plastic content from advanced (chemical) recycling based on a mass balance credit approach.
The incorporation of advanced recycled content enables increased uptake of recycled content into technically challenging or highly regulated applications like food packaging, something not possible today at scale with conventional mechanical recycling, thus minimizing the reliance on virgin resources. Incorporating advanced recycling content also ensures that packaging materials are safe for direct contact with food products, providing consumers with peace of mind on food safety while protecting against gas and moisture.
The pouch also proactively addresses the upcoming EU Packaging and Packaging Waste Regulation (PPWR) recycled content quotas, which mandate specific recycled content targets for all plastic packaging by 2030 including 10% for food contact-sensitive applications. This collaboration demonstrates the ability to incorporate higher volumes of advanced recycled material without compromise on performance or safety.

ITP SpA, producing high-quality, sustainable PE films for food and industrial packaging, managed film substrate selection, digital printing, lamination, and pouch making.
Macchi, a leading manufacturer of blown film extrusion lines, provided high-performance multilayer extrusion technology.
Dow, a global materials science company, contributed advanced PE resins – including INNATE™ Precision Packaging Resins, ELITE™ Enhanced PE Resins, AFFINITY™ Polyolefin Plastomers, and BYNEL™ Adhesive Resins – combining excellent processability with top-end functional performance.
Since 1961, Macchi has been a leading company in the blown film extrusion sector. It is within this context of long-standing expertise and innovation that the technological evolution of barrier film production lines should be understood. These advanced systems offer maximum flexibility in film structure design and enable significant reductions in film thickness — delivering both material savings and improved production cost-efficiency.
This evolution also aligns with the growing demand for environmentally responsible technologies that minimize raw material consumption, facilitate packaging reuse, and support efficient end-of-life recycling. Macchi’s latest line reflects this commitment to sustainability while also addressing market needs for high-performance processing solutions.
Anthony Michael Caprioli, Macchi CEO, said “This synergy, born from the combined research and expertise of three leaders in their respective fields, represents a key milestone in shaping the future of the plastics industry.”
ITP, an Italian family-owned company with over 50 years of expertise in flexible packaging, specializes in PE film extrusion with advanced single-bubble and triple-bubble technology. Thanks to its fully integrated production, ITP ensures rigorous control across every step of the process. This end-to-end oversight enables the optimization of film recyclability without compromising the technical performance required in the food & beverage sector. As a result, ITP delivers high-performance Mono-PE multilayer structures, fully aligned with the market’s growing demand for sustainable packaging — combining innovation, safety, and the excellence of Made in Italy.
“Through this collaboration, ITP highlights its expertise in PE extrusion to provide high-performance films with advanced recycled content, fully compliant with upcoming PPWR requirements and ready to meet future market challenges,” said Carlo Poggi, Managing Director of ITP.

The new pouches will be officially showcased at the upcoming K 2025, the world’s leading event for plastics and packaging technologies, in Dusseldorf from 8-15 October, on display at the Dow and Macchi booths. Visitors will have the opportunity to see firsthand the outcome of this industrial collaboration and learn more about the technologies behind the project.