PCR Blown Film

What Is PCR Blown Film and Why Does It Matter?

When you pick up a shopping bag, a package of snacks, or even the stretch film wrapped around a pallet, chances are you’re looking at a product made through a process called ‘blown film extrusion’. Now, this everyday packaging is entering a new chapter with the introduction of ‘PCR blown film’—a more sustainable alternative that’s helping the plastics industry close the loop.
PCR film is an environmentally friendly stretch film made from recycled waste. It's made using a blown extrusion process and infused with post-consumer recycled plastic resin. PCR resin is repurposed into a strong, durable plastic stretch film.

First, What Is Blown Film?

Blown film is made by melting plastic pellets (usually polyethylene) and forcing the molten plastic through a circular die. The material is inflated like a bubble, cooled, and then flattened into thin layers of film that can be wound onto rolls. These rolls are later converted into bags, wraps, and packaging films.
It’s a flexible, efficient process—and that’s why it’s used almost everywhere in the packaging world.

What Does PCR Mean?

PCR stands for ‘Post-Consumer Recycled’. It refers to plastics that have already been used and collected—for example, recycled shopping bags, bottles, or packaging films. After being cleaned and reprocessed, this material is turned back into pellets that can be used again in manufacturing.
When PCR resin is used in the blown film process, the result is PCR blown film.

Why Is PCR Blown Film Important?

There are three big reasons:

1. Sustainability – Using recycled plastics reduces the demand for virgin raw materials and keeps plastic waste out of landfills and the environment.

2. Regulations and commitments – Many countries are requiring packaging to include a minimum percentage of recycled content. At the same time, global brands are setting their own sustainability targets.

3. Circular economy – By giving plastic waste a “second life,” PCR blown film helps move the packaging industry toward a more circular system where materials are reused rather than discarded.

Challenges in Making PCR Blown Film

Of course, it’s not as simple as swapping virgin resin for PCR. Using recycled material brings some challenges:

• Appearance: PCR film may not be as clear or glossy as virgin plastic.
• Strength: Films with high recycled content can sometimes be less strong or flexible.
• Consistency: Since recycled plastics come from many different sources, quality can vary.

To solve these issues, manufacturers often use multi-layer film technology. For example, PCR can be placed in the middle layer, while virgin resin forms the outer layers, preserving strength, clarity, and food-contact safety.

Where You’ll See PCR Blown Film

You may already be using PCR packaging without realizing it. Common applications include:

• Retail and grocery bags
• Garbage and bin liners
• Stretch and shrink wraps
• Some types of food packaging

Looking Ahead

PCR blown film is still developing, but it’s growing quickly as technology improves and recycling systems become more advanced. In the future, even higher-quality recycled resins will allow more products—including premium packaging—to include PCR content.

For customers, the message is simple: choosing packaging made with PCR blown film supports sustainability, reduces waste, and helps close the loop on plastics.