The Downgauging Race in Flexible Packaging: What Evertis's Expansion Says About Coex Cast Tech

Evertis México poured money into expanding this 9,600-ton annual capacity coextrusion cast (Coex Cast) line because they saw brands panicking over the urgent need to make packaging thinner

Over the past month or two, I've noticed export brands shipping to the US getting very nervous as California's SB 54 (Extended Producer Responsibility legislation) approaches. Recycling infrastructure for flexible films still has massive gaps right now. To stay compliant, the fastest route is cutting plastic use right at the source

This expansion pushes Evertis's total capacity at its Pesquería site in Mexico past 44,000 tons. Their traditional strength was rigid packaging, but expanding into ultra-thin flexible film is all about capturing the perks of food and beverage brands cutting costs and material volume. This is a supply chain survival game. If your material can't get thinner, it gets replaced

It solves the physical contradiction between being thin and staying durable

Coextrusion cast film works by melting multiple plastic resins with different properties and extruding them through a single die to create a multi-layer film in one shot. Think of it like baking a mille-feuille, but pressed flat in a single pass

・Monolayer films: Cheap and easy to make, but reaching high moisture and gas barrier ratings requires added thickness, which goes completely against reduction goals

・Traditional lamination: Gluing several distinct films together involves extra processing steps, leaves adhesive residue that interferes with recycling, and rarely reaches ultra-thin gauges

・Coex cast: Directly layers different resins together. The outer layer resists scratches and takes ink well, the core blocks oxygen, and the inner layer provides heat sealing. Strong physical performance, yet extremely thin. That is why Evertis invested heavily in this equipment

Don't rush to buy new machinery yet. Step one is taking inventory of your current clients' export share and packaging specs

Multi-million-dollar coex lines aren't something typical SMEs can just buy into. When brands hand you downgauging specs, here is what you can actually do in practice:

1. Check your existing structure: Lay out your current 3-layer or 4-layer laminated packaging, and when ordering from upstream suppliers, evaluate which layers could be replaced with a coex cast film

2. Test printability: Tension control with ultra-thin film on a printing press is a nightmare. Before swapping materials, always run live press tests for registration accuracy and ink drying. If the press can't handle it, you'll need to modify the tension rollers

3. Reset design specs: Shrinkage rates and seal margins will shift, so designers must re-align dieline dimensions with bag-making converters before finalizing artwork

If your project isn't at the industrial packaging tier yet and you just need standard commercial printing or short-run prototyping, check out MINDS to price your budget online, lock in the baseline specs, and then look into specialty packaging upgrades later

・Evertis adding 9,600 tons of ultra-thin film capacity highlights urgent market demand for lower thickness without sacrificing performance

・Coex cast produces multi-layer structures in one step, breaking through the physical limits of single-material films

・Under European and US EPR regulations, packaging design must factor in source reduction and material replacement right from the start

・Switching to ultra-thin film directly disrupts press tension control, making live press trials and dieline adjustments non-negotiable

This 9,600-ton line is just one snapshot. Equipment makers aren't just competing on raw output anymore, they're racing to see who can produce thinner films with finer layer divisions. For Taiwanese plants, this is a very real shakeout. If you lack the capital to invest in new equipment, find dependable suppliers who can deliver these advanced substrates, and shift your edge toward precision film printing and post-press finishing. Don't fight a losing battle on film production. Compete on how well you master new materials

・Evertis México Expands Flexible Film Capacity With Advanced Coex Cast Line