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XPP: The World's First Polypropylene Designed For Form Fill Seal Applications
Safe, efficient, and recyclable rigid FFS packaging material alternative to polystyrene.
A Better Way Forward for Form Fill Seal
XPP isn’t just another material; it’s a solution built for what’s next. When regulations, recyclability, and rising expectations made polystyrene a problem, we developed a better answer. XPP is everything manufacturers have been looking for: food-safe, fully recyclable, and capable of delivering the same performance you’ve counted on for years. And yes, it still snaps.
The Advantages of XPP® Polypropylene
Historically, polystyrene (PS) has been the material of choice for rigid form fil seal (FFS) food packaging applications. But the material comes with several disadvantages, from sustainability issues and limited recycling options to health and safety concerns. 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.
Improved Performance
XPP® has superior performance over traditional PP, has similar performance to PS, and is superior to PET in weight, temperature resistance and process compatibility on FFS lines.
Process Compatible
Because of its functional similarity to PS, XPP® can be used as an effective replacement with existing processing equipment for lower CAPEX requirements than alternative PS replacement options.
Enhanced Efficiency
Lightweight, low-density XPP® offers a significant density reduction in comparison to PS and PET. This results in higher yield, reduced cost, and reduced material consumption.
Compliant with Regulatory Requirements
XPP® is FDA-Approved for Food Contact, is compliant with European Union (EU) Framework Regulation 1935/2004 and is produced under FSSC / ISO 22000 standards.
Sustainable & Recyclable
While other materials such as PS and barrier PET have limited recycling options, XPP® can be Post Consumer Recycled even when coextruded with EVOH.
Simplified & Food-Safe
XPP®™ is a simplified, safe solution free from phthalates and BPAs and ensures compliance with Proposition 65 guidelines.
Discover the Benefits of XPP®
XPP provides improvements to key functional properties, to offer similar characteristics to current PS packaging – including the characteristic “SNAP” of form-fill-seal multi-packs – in the form of a more efficient, sustainable and cost effective solution.
Watch the video to see what XPP Polypropylene Solutions can do for you!
The Next Evolution in Form Fill Seal Rollstock
For Rigid Polypropylene Food Packaging
Increased Barrier for Food Packaging with XPP + RE-BA
XPP serves as a replacement for PS across a wide range of applications, but we’ve taken the material even further with our next advancement: XPP with reimagined barrier technology (RE-BA) takes a new approach for barrier applications. Rather than coating, or laminating materials, RE-BA creates a barrier through a tortured path when combined with XPP. The result?
XPP with RE-BA is safe for barrier food packaging applications, but it is also recyclable, more efficient, and more sustainable.
Want to find out if XPP with RE-BA is right for your application?
Reach out to our experts to discuss your packaging needs and see whether RE-BA is the material solution you’ve been looking for.
Enhanced Barrier
Improved barrier properties without the use of specialty materials or coatings:
- 90% improvement in OTR vs traditional PP
- 90% improvement in MVTR vs traditional PP
- 100% improvement in OTR vs PS
- 150% improvement in MVTR vs PS
Mechanical Improvements
Improvements to key functional properties offer process compatibility for simple PS replacement:
- Maintains PS “snapability” & “scorability” for FFS
- Increased flex modulus/stiffness
- Controlled shrink during forming
- Compatibility with existing FFS platforms
- Minimal CAPEX for equipment modifications
Increased Efficiencies
Low density solutions promote improved efficiencies & controlled cost:
- 12% yield advantage PS & 30% advantage vs PET
- Increased cost savings
- Reduced material consumption:
- 1,000,000 lbs PP = 1,120,000 lbs PS
- 1,000,000 lbs PP = 1,300,000 lbs PET
Elevated Sustainability
Lightweight PP-based solutions promote improved sustainability profile & low carbon footprint vs PS & PET:
- Recyclable (RIC #5)
- Non-mineral filled structures maintain PP density & ability to sort for recycling
- Less CO2 equivalents by weight
- Less solid waste by weight
- Lower fuel consumption & lower emissions
XPP® Polypropylene in Action
Talk to a Material Solutions Expert
Looking for the perfect packaging solution for your applications? A material solutions expert at ICPG can help you determine whether XPP® is the solution you’ve been looking for.