Bioflex: "We are convinced that EVO Fusion is the future."
Plastic bags and pouches manufactured by Bioflex impress at first glance with their high-quality craftsmanship and colorful design. They are ideally suited, for example, for packaging food and plant seeds. What is not immediately apparent: these are products made from recycled material. This aligns with the company based in León, located in central Mexico. "We strive to make everything meaningful," says Michelle Voss Díaz, Sustainability Director at Bioflex. "This includes developing packaging solutions that conserve resources and reduce the ecological footprint." The company has set itself a very ambitious goal in this regard. By the end of 2026, Bioflex aims to produce all of its packaging from materials that are both recycled from post-consumer waste (PCR – Post-Consumer Recyclate) and industrial waste (PIR – Post-Industrial Recyclate) or from materials that are recyclable.
Elaborate granulation in the standard process
So far, it has been particularly difficult to pro-duce good material from recycled plastic. After all, Bioflex typically deals with recyclate of completely varying quality. Before entering the production process, the recyclate must first be processed into granulate and then dried. Particularly PCR (Post-Consumer Recy-clate) has so far required not only elaborate preparation but also thorough cleaning. Only then is it suitable for processing in extrusion systems. Even the smallest foreign particles in blown film production can cause the bubble to burst. "The preparation is a time-consuming, cost-intensive, and energy-intensive process," confirms Voss Díaz. "There seemed to be no simple solution for recycling multimaterial."
Profile: Bioflex
Founded in 2015, the company currently employs over 900 employees. Bioflex manufactures plastic films, which are used to develop flexible and customized packaging solutions for their clients. Additionally, they print on the products. Bioflex strives for innovation and sustainability in its processes and products. Their clients include companies from the logistics and food industries, agriculture and construction sectors, as well as the chemical and pharmaceutical industries.
With EVO Fusion, film waste can be processed directly. In the meantime, the recycling specialist has set aside her skepticism. In spring 2025, Bioflex commissioned the blown film line EVO Fusion from Reifenhäuser Blown Film, whose performance fascinates Voss Díaz. The machine significantly reduces and purifies pigments and contaminants from the raw material without requiring any prior processing. It is sufficient to feed the film waste into the system, which processes it in such a way that high-quality plastic films are produced without exception. Even recyclates from laminated films and those with barrier layers can be processed by EVO Fusion, as long as the proportion of barrier material, such as EVOH, does not exceed five percent. Voss Díaz confirms: "The material becomes so clean and perfect with EVO Fusion, as I have never seen before." Multimaterial films of various compositions can thus be processed easily and in a single step without pre-processing, the so-called fluff-to-film process.
Daniel Pizarro, Area Sales Manager at Reifenhäuser, is well-acquainted with the new technology: “The special feature of EVO Fusion is that we rely on two twin-screw extruders. In these, the recyclate is first thoroughly mixed and distributed.” In the subsequent processing steps, foreign substances such as printed color pigments and impurities are removed through degassing. The homogenized and melted recyclate then flows into the dies, where films with up to five layers are produced using blown film technology. Bioflex typically manufactures a PET/PE mix in this way. “With this new technology, plastic producers can significantly streamline their production process, as granulation and purification are no longer required. This allows them to save the necessary equipment and up to 40% energy,” Pizarro highlights the key savings potential.
Film quality also convinces buyers
Bioflex produces a variety of plastic products on the EVO Fusion line, ranging from small bags and stand-up pouches to mailing bags, packaging films, and secondary packaging. "Before we started production on EVO Fusion, we conducted tests," reports Voss Díaz. "Among other things, they showed that we can produce recycled material that is excellent for use in the construction industry. The film material is very suitable for packaging and protecting powdered waterproofing agents." Additionally, the recycled material processed into mailing bags helps ensure the safe transport of packaged products. And how did Bioflex's customers react? "At first, they were somewhat hesitant about the recycled materials," Voss Díaz recalls. "They were particularly concerned about the film quality. However, with the first products, we were able to dispel these concerns immediately."
Four advantages for Bioflex through the EVO Fusion technology:
- Energy savings by eliminating the need for labor-intensive granulation of the recyclate beforehand. (Savings potential of up to 40%)
- Processing of recyclate with inconsistent quality (PCR and PIR), including efficient purification.
- High system efficiency thanks to streamlined production.
- Reduced waste, as it can be directly recycled and processed into a new product.
EVO Fusion reduces waste and facilitates circular economy
On the films and packaging produced with EVO Fusion, Bioflex also applies a print. This explicitly indicates that the film is made from recycled plastic and manufactured using EVO Fusion. "This is how we embody the idea of the circular economy and demonstrate that we are not engaging in greenwashing," emphasizes Voss Díaz, highlighting a very central aspect for Bioflex. Additionally, EVO Fusion solves another Bioflex problem: A high proportion of self-produced waste could not previously be reintroduced into blown film lines because the quality of the recyclate was insufficient for film production. The company resolved this dilemma by producing tables and chairs from it. However, Bioflex is not actively pushing into this market. Voss Díaz states: "With EVO Fusion, we can now process the waste into packaging material, thereby avoiding waste. In the future, we also want to accept production waste from our customers, which they would otherwise have to dispose of at a cost."
Bioflex is extremely satisfied with the acquisition of the EVO Fusion blown film line. As the first company on the American continent, it is utilizing this technology. "We are convinced that EVO Fusion is the future," emphasizes Michelle Voss Díaz. "Given the amounts of plastic being produced, we need the circular economy. Therefore, every plastic manufacturer should have and use the opportunity to recycle multi-materials. With EVO Fusion, we have been achieving this very convincingly and easily for a few months now."
Are you also considering processing PCR and PIR recyclates? EVO Fusion sounds like an appealing option? Contact our representatives at Reifenhäuser Blown Film:
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