Resource Efficient Innovations Database (REID)

Direct extrusion PET process

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Direct extrusion PET process
Direct extrusion PET process produces high clarity PET with tight thickness tolerances.
In Use – The technology is available globally, marketed under the brand name DPET™.

Packaging Reduction, Resource efficiency (e.g. filling line efficiency)

Product Categories
Food, Home Improvement, Household & Personal Care, Other

Relevant Materials
Plastic – Flexible, Plastic – rigid

Relevant Packaging Formats
Flexible & Films

Supply Chain Phase
Production, Raw materials / Ingredients


This technology is based on a unique direct extrusion process which involves heating raw materials in single stage resin reactors, then pumping the resin in its molten form under consistent pressure directly from reactors through to extrusion, producing films of very high clarity and with tight thickness tolerances of +/-1%. The resulting DPET™ films also have excellent thermoforming characteristics and high clarity.
The tight thickness tolerances achieved via this process have enabled gauge reductions of 4% to 8% with several US customers.
For example, a 300mu sheet at normal thickness tolerances of +/-8% will result in a material thickness variance of +/-24mu. In this case the manufacturer claims they can reduce the target gauge to 280mu and maintain a +/-1% thickness tolerance, which equates to only 2.4mu variance.
As well as saving material, the approach also saves energy and reduces cost by eliminating intermediate production processes.
This technology has been developed and is being marketed by Octal.
The content of this entry has been obtained from publicly available information sources only (e.g. Press articles, website and trade press releases).  The content has not been validated by the technology supplier and no additional information has been provided by the technology supplier.

Potential Benefits

The greatest potential benefit of this technology is in reducing the amount of packaging material used by achieving tight tolerances of material thickness.
Also, independent studies by US consultants identify energy savings and an easily identifiable 20% reduction in CO2 emissions, purely from the removal of the drying and reheating process. In addition, there are no emissions generated by the movement of separately produced resin reprocessed material to the sheet making plan.

Intellectual Property

Octal has a patent pending on this technology.

Consultant View

Conversion processes that offer consistent gauge reductions, with the added bonus of high clarity films, are of key importance in the supply chain. Especially as, up until recently, the majority of packaging cost out exercises have been limited to the packer/filler and retailer end of the supply chain, with suppliers often failing to identify sufficient cost out opportunities higher up the supply chain.

Contacts and Further Information

Company details:
Octal Headquarters
Sultanate of Oman
Tel: +968 24 730 700

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