Amcor has expanded its manufacturing site in Lugo di Vicenza, Italy, adding a new production line, laboratory and automated warehouse to increase output of recycle-ready packaging materials. The investment supports the company’s development of high-barrier films designed for a wide range of food, beverage, pet food and healthcare applications.

The expanded facility will focus on producing high-barrier recycle-ready films used in packaging formats such as pouches and lidding. These materials are designed to maintain strong protective performance while enabling compatibility with recycling systems.

The investment comes as packaging producers and consumer brands prepare for new regulatory requirements across Europe. The European Union’s Packaging and Packaging Waste Regulation (PPWR) is expected to require packaging to be recycle-ready by 2030, increasing demand for materials that meet both performance and regulatory criteria.

Amcor’s Lugo di Vicenza site now includes an additional production department dedicated to these materials. Among the products manufactured at the facility is AmLite HeatFlex™, a packaging material developed for retort applications that require high heat processing.

Retort packaging is widely used for products such as wet pet food, ready meals, microwavable rice and baby food. Packaging used in these applications must withstand high temperatures during sterilisation while preserving product safety and shelf life.

The AmLite HeatFlex material is designed to maintain barrier protection against oxygen and moisture while also being compatible with recycling streams. This allows brands to move away from traditional multi-material packaging structures that can be difficult to recycle.

The expansion covers almost 7,000 square metres and includes infrastructure supporting each stage of film production. A dedicated quality control laboratory has been added to monitor material performance and ensure consistency across production batches.

The site also features a new automated high-density warehouse designed to store materials during the curing stage of production. Temperature-controlled chambers allow films to stabilise before they are converted into finished packaging products.

According to Amcor, controlling these conditions helps maintain uniform barrier performance and durability in the final packaging format. This is particularly important for applications such as retort packaging where materials must tolerate high temperatures and pressure.

The facility’s additional capacity is intended to help brands transition to packaging formats that align with upcoming European regulatory requirements. Many companies in the food and consumer goods sectors are reviewing packaging portfolios as PPWR approaches implementation.

The regulation forms part of the EU’s wider effort to reduce packaging waste and increase recycling rates across member states. It sets new expectations for recyclability, waste reduction and material efficiency within packaging supply chains.

Elena Peron, Plant General Manager at the Lugo di Vicenza site, recognised the role of the local team in delivering the project.

“This new facility is the result of Amcor’s pledge to develop all our packaging to be recyclable, reusable or compostable. This expansion, combined with the Amcor team’s expertise, will support our customers in making the switch to recycle-ready packaging and contribute to a more circular packaging industry.”

Packaging producers are under increasing pressure to redesign materials in response to both policy developments and consumer expectations. Retailers and brand owners are also setting their own packaging commitments as part of wider environmental targets.

Flexible packaging plays a major role in global food distribution due to its lightweight structure and ability to extend shelf life. However, many traditional flexible packaging materials combine multiple layers of plastic and aluminium that are difficult to process in recycling systems.

Recycle-ready alternatives aim to replace these structures with materials that deliver similar barrier performance while remaining compatible with existing recycling technologies. Manufacturers across the sector are investing in new production capacity and material science to support this transition.

Amcor’s investment in the Lugo facility reflects the scale of change currently underway in the packaging industry. Companies are seeking to balance product protection, cost efficiency and recyclability as regulatory deadlines approach.

The Italian facility has become one of the company’s key sites for high-barrier film production in Europe. The addition of new production infrastructure is expected to increase output of recycle-ready films while supporting development of new packaging formats.

AmLite HeatFlex, one of the materials supported by the new production line, targets applications that require heat treatment. Products such as pet food and ready meals rely on retort processing to ensure long shelf life and product safety.

Packaging for these products must maintain barrier integrity under demanding processing conditions. Materials that meet these requirements while also being compatible with recycling streams are becoming an important focus for packaging development.

As regulatory frameworks evolve and brand commitments expand, manufacturers are increasing investment in technologies that support recyclable packaging formats. Facilities such as the Lugo di Vicenza expansion are expected to play a role in meeting that demand across European markets.