Walki, Dow’s  new matte MDO-PE pouch targets frozen food with PPWR-ready mono-material design

SPAIN – Walki and Dow have jointly developed a mono-material MDO-PE pouch with a matte finish for frozen food applications, creating an all-PE laminate that meets design-for-recyclability guidance while delivering the stiffness and barrier performance needed to replace conventional polyester-based structures.

The collaboration between Walki Plasbel R&D manager Juan Angel Ruiz Salazar and Dow EMEA senior TS&D specialist Ksenija Maksimovic produced a flat-bottom pouch prototype initially filled with frozen gyoza dumplings and showcased at interpack 2026. 

MDO-PE can replace traditional print web films such as oriented polyester and, when paired with a PE-based sealant film, forms an all-PE laminate that complies with recyclability requirements. 

The development responds to growing demand for lighter, more material-efficient alternatives to rigid packaging formats as brand owners prepare for the Packaging and Packaging Waste Regulation.

How Dow’s AFFINITY Plastomers Overcome MDO-PE’s Heat Sensitivity Challenge

The sealing performance presented a critical technical hurdle because the outer MDO layer is sensitive to heat once laminated. 

The team applied a sealant layer made from Dow’s AFFINITY Polyolefin Plastomers, specifically designed to activate and seal at low temperatures to avoid damaging the MDO layer during the sealing process. 

Ksenija Maksimovic explained that this approach reduces film blocking, improves machinability, delivers excellent high-speed packaging line performance, and enables robust sealing. 

She added that this enables higher extrusion output, equipment efficiency, and overall cost savings when producing recyclable packaging.

Why Matte Finish and Printability Matter for Premium Frozen Food Branding

MDO films typically deliver a glossy surface, but the matte finish offers a premium appearance that conveys quality and shelf presence. 

Juan Angel Ruiz Salazar noted that there had been a need for a solution that delivers the functional performance of MDO-PE but with a premium matte appearance. 

The pack’s high-quality printability enables product differentiation at point of sale, especially as supermarkets increasingly replace open freezer cabinets with transparent glass-door freezer systems where packaging visibility plays a greater role in attracting consumer attention. 

The material is also suitable for dry foods such as cereals and fresh food packaging using modified atmosphere packaging with gas. 

Jonas Skuthälla, Head of Sales for Flexible Packaging at Walki, said that when designed for circularity, plastic packaging plays a critical role in extending shelf life and preserving food quality, with the priority being to keep materials in use and within the loop.

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