Monomaterial flexible packaging: the Bimbo Little Bites case study

Grupo Bimbo needed to make the packaging for its Little Bites muffins easier to recycle without compromising freshness or quality. Through CIRCULAR PACK, a joint service provided by Comexi and AIMPLAS, its multimaterial flexible packaging was replaced with monomaterial structures tailored to each destination country. These were produced in a pre-production run and validated by Bimbo. Find out how the original packaging was analysed, how the new structures were selected and what results the brand achieved.

Key project facts

Client: Grupo Bimbo (Mexico)
Product: Little Bites, chocolate chip muffins
Service: CIRCULAR PACK (Comexi + AIMPLAS)
Challenge: Switching from multimaterial flexible packaging to a recyclable monomaterial solution
Markets: United States and Brazil, with a structure designed for each market
Result: Packaging designed for recycling, with a lower carbon footprint while maintaining the product’s freshness and quality

Why is multimaterial flexible packaging difficult to recycle?

Many flexible food packaging solutions combine several layers made from different materials. Each layer serves a specific purpose, such as providing barrier properties, strength, sealing or printability.

The problem arises at the end of the packaging’s life. These layers cannot easily be separated, making the packaging difficult to recycle mechanically. Monomaterial packaging, made from a single polymer family, makes recycling much easier.

The challenge is to achieve this without compromising the product’s requirements: product preservation, processability on the packaging line and high-quality printing.

What challenge did Grupo Bimbo face?

Little Bites is one of Bimbo’s leading products. Its packaging was multimaterial, and the company wanted a more sustainable alternative.

The objective was to assess, select and produce a pre-production run of a monomaterial flexible packaging structure that met all the product’s requirements. The freshness and quality of the muffins had to remain unaffected.

What is CIRCULAR PACK?

CIRCULAR PACK is a joint service provided by Comexi, a manufacturer of machinery for printing, laminating and converting flexible packaging, and AIMPLAS, the Plastics Technology Centre. It combines AIMPLAS’s expertise in material assessment and selection with Comexi’s experience in efficient and sustainable industrial processes.

The service can be tailored to each company through three levels:

Basic: Assessment of the existing packaging and proposal of theoretical alternatives.
Standard: Includes everything in the Basic level, plus production of a pre-production run of the proposed packaging in an industrial environment.
Plus: Includes everything in the Standard level, plus calculation of the overall carbon footprint and certification of the packaging’s recyclability according to RecyClass.

How was the project with Bimbo carried out?

The project covered the entire packaging process, from pre-press and inks through to final manufacture. It was organised into three phases:

Analysis of the original design. The existing packaging was assessed in terms of materials, manufacturing process, carbon footprint and recyclability.
Design of the CIRCULAR PACK study. Alternative structures were proposed, the optimum structure and processing method were selected, the potential reduction in CO₂ emissions was assessed, and a pre-production run was produced. Two structures were designed: one for the United States and another for Brazil.
Validation by Bimbo. The company validated both the theoretical study and the pre-production run, and assessed the project as a whole.

As a result, Bimbo received a report containing the technical parameters required to take the new packaging into industrial production.

Why was a different structure designed for each country?

Each country manages packaging waste differently, including how it is collected, sorted and which materials are actually recycled.

For this reason, CIRCULAR PACK selects recyclable structures according to the destination market. In Bimbo’s case, two structures were developed: one for the United States and another for Brazil.

What results did Bimbo achieve?

♻️ Two monomaterial flexible packaging structures for Little Bites, one for the United States and another for Brazil, designed to be recyclable in their respective markets.

📉 A lower carbon footprint, thanks to material selection and improved recyclability.

🧁 The same freshness and quality as with the previous packaging.

✅ A validated pre-production run, together with the technical parameters required for industrial-scale production.

“CIRCULAR PACK has provided us with a genuinely sustainable solution for the multimaterial packaging of one of our leading products, Little Bites. We now have environmentally friendly packaging designed for recycling, with a lower carbon footprint thanks to material selection and recyclability, while maintaining the freshness and quality of the product. We are very pleased to have worked with Comexi and AIMPLAS on this major challenge for the company.” – Alejandro Rodriguez, Global R&D Manager at Grupo Bimbo.

Why is this case study relevant to other food brands?

Pressure to make packaging recyclable is increasing across all markets. In the European Union, the Packaging and Packaging Waste Regulation (EU) 2025/40 (PPWR) requires all packaging to be recyclable by 2030.

The Bimbo case study demonstrates that switching to monomaterial packaging is a viable option for a high-volume consumer product, provided the solution is thoroughly validated. This includes the material, printing, processing, food preservation and waste management system in the destination country.

How can CIRCULAR PACK help with your packaging?

If you want to redesign your flexible packaging to make it recyclable, AIMPLAS and Comexi can support you from the assessment of your existing packaging through to the production of a pre-production run in an industrial environment and certification of its recyclability.

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Frequently asked questions

What is monomaterial flexible packaging?

It is flexible packaging made from a single polymer family rather than several layers of different materials. This facilitates mechanical recycling because incompatible materials do not need to be separated.

Does monomaterial packaging preserve food just as well?

It can, but this must be validated for each product. In the case of Little Bites, Bimbo confirmed that the new packaging maintains the product’s freshness and quality.

Is recyclable packaging recyclable in every country?

Not necessarily. Recyclability depends on how packaging waste is collected, sorted and recycled in each country. The structure should therefore be designed with the market in which the waste will be generated in mind.

What does the CIRCULAR PACK service include?

There are three levels: an assessment of the existing packaging with theoretical alternatives; production of a pre-production run in an industrial environment; and, in the most comprehensive option, calculation of the carbon footprint and certification of recyclability according to RecyClass.

How is the recyclability of flexible packaging certified?

One option is RecyClass, a European methodology that assesses packaging compatibility with recycling processes. CIRCULAR PACK includes this certification in its Plus service.