Now that Mars files its own EPR reports as the obligated producer, its packaging specs ask suppliers what is in and not in, detailing every ink, coating, and adhesive. Mondi says mono-material swaps cost more at first, and Plug and Play says buyers won’t pay a sustainability premium for a less functional pack.

As brands move from multi-material laminates to mono-material film or recyclable paper, that performance increasingly has to come from coatings, additives, inks, and adhesives. Startups working on barrier coatings are developing water-based dispersions, mineral and inorganic nanocoatings, and bio-based coatings meant to replace PE lamination, EVOH, PVDC, and metallization. Stillman called PFAS replacement a tougher target, because fluorinated chemistries deliver oil, grease, and water resistance all at once and set a high benchmark.

• Mars is transitioning from multi-material laminates to mono-material films to meet EPR and PPWR compliance requirements.
• Chemistry and coatings now replace physical layers, requiring expertise in barrier coatings, additives, inks, and adhesives previously handled by lamination.
• Brands must now maintain complete transparency on all components, including thin layers of ink, coating, and adhesive, and file detailed compliance reports.
• EPR fee differences can range from 4 cents to 78 cents per pound based on material classification, making accurate data and supply chain transparency critical.
• Redesigns typically take longer than expected and require balancing food safety, performance, cost, recyclability, and carbon emissions simultaneously.

Mars Packaging Innovation: Chemistry Solutions for EPR Compliance | Packaging World