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What does “Composite” mean for packaging materials?

Understand what composite packaging materials are and how to model multilayer structures in SyncForce, including the difference between laminated and co-extruded films.

A composite packaging material is a structure that consists of two or more different materials combined into one functional unit, where the materials cannot be easily separated.

Examples

  • Beverage cartons (paper + polymer + aluminium)
  • Flexible films (e.g. PET / PE or PA / PE)
  • Metallized or coated films (e.g. PET + AlOx)

In SyncForce

When working with composite materials:

  • Set Material Type = Composite
  • Define each material separately in the Composite Layers section
  • Ensure that the total material split equals 100%

This allows correct:

  • Material reporting
  • Recyclability assessment
  • Compliance documentation

Important

  • Composite refers to material composition, not how the structure is produced
  • Both laminated and co-extruded films are composites if they contain multiple materials

Laminated vs Co-Extruded Films

Composite films are often multilayer structures. These layers can be combined in two main ways:

1. Laminated (adhesive-based)

Separate films are produced first and then bonded together using an adhesive layer.

Characteristics

  • Layers are physically glued
  • Allows combining very different materials (e.g. plastic + aluminium)
  • Common for high-barrier packaging

2. Co-Extruded (no adhesive)

Multiple materials are extruded together in one process, forming a single integrated film.

Characteristics

  • Layers are melt-bonded
  • No adhesive is used (may include tie layers)
  • Often used for recyclable or mono-material structures

Key Difference

  • Laminated = layers bonded with adhesive
  • Co-extruded = layers fused during production

Typical Multilayer Structure

Flexible packaging films are usually built in functional layers:

Outside → Inside (product contact)

  • Print layer (PET, OPP)
  • Barrier layer (EVOH, Aluminium, PA)
  • Structural layer (PE, PP, PET)
  • Seal layer (PE, CPP)

Example Structures

  • PET / Al / PE
  • OPP / EVOH / PE
  • PA / PE

These are all composite materials because they contain multiple material types.

How to manage this in SyncForce

For both laminated and co-extruded films:

  • Select Material Type = Composite
  • Add each layer as a material in Composite Layers
  • Define the percentage (%) per material
  • Planned extention (Q4 2026): Position (Outer, Middle, Inner)