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High-Functioning Form-Fill-Seal (FFS) Packaging Solutions.

We specialize in tailor-made rollstock for rigid barrier and non-barrier form-fill-seal packaging applications. Choose from an innovative portfolio of materials structures that optimize efficiencies and performance for automated form-fill-seal processes.

Innovations in Form-Fill-Seal Food Packaging

Polystyrene has historically been the material of choice for a vast range of rigid form-fill-seal food packaging applications – from yogurt multi-packs, to portion control condiments, shelf-stable beverages, pudding snack packs and much more. But lack of recycling options and sustainability issues coupled with health and safety concerns have resulted in initiatives to replace polystyrene on a global scale.

Previous attempts to develop replacements for PS in these applications with traditional PP or PET have resulted in solutions that cost more, fall short on performance, cause processing issues or require significant capital expenditure to modify existing equipment – until now.

Enter XPP polypropylene solutions for form-fill-seal food packaging. ICPG’s XPP™ polypropylene is a revolutionary mono-material rollstock solution that maintains all of the positive attributes of current PS materials – processing, function, barrier protection, quality, cost – in the form of a more sustainable and recyclable solution that offers drop-in process compatibility for PS replacement made easy.

Explore XPP Polypropylene Solutions for Form-Fill-Seal (FFS) Food Packaging

Enhanced Barrier

Inherent improvements to barrier properties without the use of specialty barrier materials or coatings resulting in structure simplification and extended shelf-life potential:

– 90/90% improvement in OTR/MVTR vs traditional PP
– 100/150% improvement in OTR/MVTR vs PS
– Coextrusion with EVOH for high barrier shelf-stable applications

Drop-in Processing

Refinement of key functional properties offer process compatibility with existing FFS systems & platforms:
– Compatible with existing trimming & cutting stations
– Minimal CAPEX for equipment & tooling modifications
– No loss in cycle times or through-put

Improved Performance

High stiffness attributes provide similar characteristics to current PS packaging functionality & processing:
– Maintains PS “snapability” & “scorability” for FFS
– Increased flex modulus/stiffness of 450,000 Psi vs 300,000 Psi for PS
– Controlled shrinkage mitigates downstream processing issues

Simplified & Safe

Simplified solutions with inherent barrier protection results in a clean, safe & simplified solution using no additives, mineral fillers, or specialty coatings providing:
– Superior organoleptic properties for food packaging applications
– High heat tolerance for freezer – microwave applications
– Compliant with Proposition 65 guidelines

Check All the Boxes

Economics or Environment?

With XPP you don’t have to choose. Our mono-material XPP Polypropylene Solutions maintain all of the positive attributes of current materials: processing, function, barrier protection, quality – all the form of a more sustainable, recyclable and cost effective solution vs PS and PET alternatives.

The demand for plastic waste reduction and more sustainable packaging solutions have increased global concerns regarding the sustainability and recyclability of single use packaging. ICPG’s XPP rollstock solutions allows converters and brand owners the opportunity to economically and effectively replace PS in form-fill-seal food packaging with a more sustainable solution, without sacrifice to barrier protection or performance.


Light-weight PP-based solutions promote improved sustainability profile & a reduced carbon footprint vs heavier materials like PS & PET:
– Less CO2 equivalents by weight
– Less solid waste by weight
– Lower fuel consumption & lower emissions


In comparison to other barrier material structures produced from a complex mix of materials, XPP solutions are produced from polypropylene materials resulting in a more recycle-friendly solution. Comparative barrier materials such as HIPS/PVDC must be identified using the Resin ID Code #7, which limits opportunities for recycling and re-use in other applications.

XPP Polypropylene Solutions are:

– Identifiable as RIC #5 for both enhanced barrier & high barrier
– Structures pre-qualified with How2Recycle
– Non-mineral filled structures maintain PP density & ability to sort for recycling

Resource Efficiency

Light-weight and low-density XPP material solutions offer a 12% density reduction in comparison to PS and a 30% density reduction in comparison to PET. This density reduction results in a higher yield (more parts) during thermoforming processes, reduced cost and reduced material consumption in comparison to PS and PET:

– 1,000,000 lbs PP = 1,120,000 lbs PS
– 1,000,000 lbs PP = 1,300,000 lbs PET

View the XPP photo gallery and download the XPP Product Sheet to learn more today!

  • Form-Fill-Seal

Make It Yours

  • Market Applications

    ● Aseptic FFS
    ● Non-aseptic Form-Fill-Seal FFS

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  • Material Solutions

    ● HIPS
    ● Polypropylene
    ● XPP Enhanced Barrier Polypropylene
    ● EVOH

    Examine Our Materials
  • Performance Features

    ● Blended Propylene for added stiffness and impact resistance
    ● Customized barrier specifications
    ● Enhanced OTR & MVTR PP for shelf-life extension
    ● High & low temperature clarified PP
    ● Snap-able PP
    ● XPP for PS replacement

    Explore Our Specialty Materials
  • Structure Configurations

    ● Monolayer
    ● Barrier extrusion lamination
    ● Multi-layer coextrusion
    ● Symmetrical & asymmetrical structures

    Assess Our Extrusion Capabilities
  • Proven Excellence

    Learn about our longstanding commitment to fully certified food packaging solutions.

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  • Specialty Solutions

    Explore our selection of specialty solutions for form fill and seal packaging applications.

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  • Reliable Resources

    Uncover an expertly crafted collection of food packaging know-how in our in our Industry Insights blog.

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  • Sustainably Focused

    Discover how our methods and materials reduce, reuse, recycle and reinforce our everyday dedication to sustainability.

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  • Superior Support

    Trying something brand new? Tap into our on-site technical support services to help you through the development process— one material at a time.

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