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Evertis has expanded its flexible packaging capabilities in North America with the installation of a new advanced Coex Cast film production line at its manufacturing site in Pesquería, Nuevo León, Mexico.

The investment, completed in August, adds more than 9,600 metric tonnes of ultra-thin flexible film capacity to the market and takes total manufacturing capacity at the Evertis México site to more than 44,000 metric tonnes.

The company said the new line represents a significant expansion of its capabilities in high-performance, PET-based flexible films, while helping bridge the gap between Evertis’ established expertise in rigid packaging and growing demand for ultra-thin flexible materials.

The technology is expected to support food and beverage brands, processors and packaging converters seeking to reduce material use while maintaining the performance required for increasingly complex packaging applications.

Manuel José Matos Gil, CEO of Evertis, said: “Bringing advanced COEX CAST technology to Evertis México extends our portfolio into ultra-thin flexible films at a moment when our customers are asking for higher performance from less material. It is a deliberate step in the evolution of Evertis.”

The new production line features a six-extruder configuration capable of producing film structures of up to eight layers, allowing barrier properties to be tailored to individual packaging applications.

According to Evertis, its in-house coextrusion technology can support customised formulations, the integration of recycled content and the development of structures designed to remain compatible with existing PET recycling streams.

A key feature of the new capability is its potential for downgauging, enabling packaging producers to reduce material per pack while maintaining mechanical performance. This could help lower pack weight and material intensity without compromising the barrier, optical clarity and surface finish required for consumer-facing food and beverage packaging.

Matt Smith, business development director at Evertis USA, said: “North American processors and brand owners have been clear with us: they want films that run reliably at speed, hold their shape through complex packaging applications, and reduce material without compromising performance."

Smith continued: “The new COEX CAST line is engineered around these exact requirements. It strengthens our ability to better serve the US market with a premium packaging offering that our customers can build their brands around.”

Evertis said the new line also forms part of its broader circular economy strategy, with the technology designed to support material reduction and the use of recycled content in flexible packaging structures.

By producing thinner, high-performance PET films, the company aims to help brands reduce overall material consumption and packaging weight. The coextrusion capability will also support the development of flexible barrier structures designed to be compatible with established PET recycling systems.

The expansion in Mexico comes as Evertis continues to invest in its wider North American manufacturing network.

The company recently announced plans to build a new production facility in Columbia, South Carolina, representing a total investment of US$100 million. The plant is scheduled to begin operations in the first quarter of 2028, with first commercial sales expected in the second quarter of the year.

Together, the Mexican expansion and planned US facility underline Evertis’ strategy to increase its regional manufacturing capabilities as demand grows for high-performance packaging materials that balance food protection, functionality and circularity.

Founded in 1959, Evertis specialises in PET-based barrier films for food packaging and other applications. The company operates manufacturing sites in Portugal, Brazil, Italy and Mexico and continues to focus on increasing recycled content, improving recyclability and reducing the carbon footprint of its packaging solutions.