Fully recyclable resealable Doypack through smart supply chain collaboration

Sector Food industry

In the packaging industry, sustainability, convenience and production efficiency are increasingly coming together. Manufacturers are looking for packaging solutions that are easier to recycle, can be processed efficiently and meet consumer expectations.

Together with VDL Packaging and Hatzopoulos, Supertape has developed an innovative packaging solution: a resealable Doypack made from mono-material PP. By carefully aligning the machine, film and resealable tape, this collaboration has resulted in a future-proof solution for flexible packaging.

The challenge

Resealable packaging offers consumers a high level of convenience. Products stay fresh for longer, packaging becomes easier to use and food waste can be reduced. At the same time, traditional resealable solutions, such as plastic zippers, involve additional material use, higher costs and greater complexity in the packaging process.

For manufacturers, this raises a clear question: how can resealability be added to flexible packaging without compromising on recyclability, efficiency and processability?

The solution: three technologies in one integrated system

This case demonstrates how supply chain collaboration can lead to a smart and scalable packaging solution. The Doypack combines three complementary technologies: a VFFS machine from VDL Packaging, mono-PP film from Hatzopoulos and a resealable tape solution from Supertape.

1. The machine: efficient inline tape application

The UVA Dynamic Pure VFFS machine from VDL Packaging forms, fills and seals the Doypack in one continuous process.

Within this configuration, the resealable tape is applied inline using an integrated tape applicator. This allows resealability to be added without unnecessary additional process steps or complex modules. As a result, the solution is compact, efficient and suitable for industrial packaging lines.

2. The film: mono-material with high barrier properties

The packaging uses X-CYCLE film from Hatzopoulos: a polypropylene film with high barrier properties.

This film has been developed with recyclability within existing plastic streams in mind, while maintaining product protection. This is important for applications such as snacks, coffee, pet food, nuts and other dry food products.

3. The resealing solution: lightweight tape as an alternative to the zipper

Instead of a traditional plastic zipper, a double-sided resealable tape from Supertape is used.

This tape makes the packaging easy to open and reseal. The solution is lightweight, efficient to process and aligns with the mono-material structure of the packaging. Because the tape adds only a limited amount of adhesive to the total packaging weight, the material structure remains simple and well aligned with recycling objectives.

The result: a future-proof resealable packaging solution

By combining machine, film and tape, a packaging solution is created that responds to the changing demands of the market. This case shows that resealability, recyclability and production efficiency can go hand in hand when all components are aligned from the very beginning.

The key benefits:

resealable Doypack based on mono-material PP;
designed with recyclability in mind;
suitable for inline processing on VFFS packaging lines;
a simpler and lighter alternative to traditional zipper solutions;
lower complexity in machine integration;
fewer changeovers thanks to long tape rolls;
user-friendly for consumers;
supports longer freshness and reduced food waste;
suitable for applications such as snacks, coffee, pet food and dry food products.

Ready for the packaging challenges of tomorrow

This collaboration highlights an important development in the packaging industry: the shift from optimising individual components to integrated supply chain solutions.

By aligning the machine, material and resealable functionality as early as the design phase, a solution is created that is both economically and ecologically attractive. For manufacturers in the food industry, this resealable Doypack offers a concrete and scalable alternative to existing packaging concepts with zippers.

The role of Supertape

Supertape develops and manufactures tape solutions for resealable flexible packaging. In this case, our resealable tape makes it possible to add convenience to a recyclable packaging concept, without making the production process unnecessarily complex.

Our tape solutions are suitable for machine application and can be tailored to different packaging materials, product categories and line configurations.

Want to know more?

Would you like to explore whether resealable tape is suitable for your packaging or production line?

Supertape is happy to support you with:

technical integration of tape application on VFFS systems;
advice on tape solutions for flexible packaging;
coordination with film and machine partners;
testing options and validation within your production environment.