Our company has been at the forefront of sustainable packaging efforts. As early as 2007, we introduced three packages made from polylactic acid using EarthFirst PLA films. These were among the first compostable structures commercialized in the wide web flexographic industry. We surmounted several challenges working with this film. For example, users cannot punch holes in the film for respiration because the holes weaken the film so much that tears propagate easily. This issue hindered its use because PLA film does not allow oxygen in, which renders it unusable for fresh produce applications. We solved this problem by using our laser microperforator to make 110 micron holes, big enough for oxygen to flow. The laser also creates a hole with reinforced edges, which means the holes will not cause tears.

We've also created a line of laminated structures that use PLA, often married to a traditional plastic film. This improves the stability of the package and makes it easier to seal on form fill seal equipment. We currently laminate PLA as thin as 80g to a variety of other structures of various thicknesses.

Emerald Packaging is also working with potato starch-based films and cellulose-based films to develop new compostable flexible packages.