QVC UK will cut approximately 50 tonnes of virgin plastic and 148,000 tonnes of carbon (tCO₂e) annually after switching its Liverpool fulfilment centre to a graphene-enhanced polythene autobagging film developed by Manchester-based Duo Packaging, the manufacturer said.

The product, branded 2DPETM, was developed in partnership with the University of Manchester's Graphene Engineering Innovation Centre (GEIC). Industrial trials with GEIC and the live-shopping retailer showed the film achieved up to 35% higher material strength than the standard autobagging film and lifted the recycled content in QVC's packaging from 45% to 60%.

Where is the film being used?

Duo is deploying 2DPETM initially as e-commerce mailing bags and form-fill-seal autobag film used by retailers for clothing, cosmetics, homewares and toys. QVC has replaced its standard autobagging film at the Liverpool fulfilment centre, which handles live-shopping orders shipped direct to consumers.

The company claims the graphene-enhanced polythene retains tensile strength and tear resistance while enabling thinner gauges and reducing energy use during conversion.

The 50-tonne virgin-plastic saving applies to a single fulfilment centre. Per-site figures from QVC indicate the formulation can absorb a 15-point recycled-content lift without mechanical failure on automated bagging lines running at speed.

Who developed 2DPE?

Duo Packaging is a Manchester-based flexible packaging manufacturer co-owned by Zoe Brimelow (Brand Director) and Dale Brimelow (Operations Director). Zoe Brimelow led the research partnership with GEIC and led 2DPE's development from concept through to commercial production.

She said: "Retailers are facing cost pressures, tightening regulations, growing customer expectations, market volatility and supply chain challenges. There was nothing on the market that could solve all of these challenges without having to make some type of trade-off. We knew graphene was the answer to solving this challenge."

R&D was funded through the Innovation Navigator Programme, run from the GM Business Growth Hub and launched by Greater Manchester Mayor and current Prime Minister Andy Burnham.

Why is the timing commercially significant?

Flexible film is one of the most problematic streams in UK packaging recovery — high-volume in e-commerce, low in mechanical recyclability.

The Plastic Packaging Tax applies to packaging containing less than 30% recycled plastic and is currently set at £217.85 per tonne for any volume above that threshold.

The packaging Extended Producer Responsibility (pEPR) regime, in development, carries modulated fees calibrated to recyclability performance and recycled content.

Duo's 45%→60% recycled-content jump therefore sits well above the 30% tax threshold. That removes immediate tax exposure for converters and positions the film for modulated EPR credits under the new regime.

Dale Brimelow said: "There is growing demand for packaging that is recyclable, uses higher levels of recycled content, uses resources more efficiently and is lightweight by design. Utilising graphene will transform the application of flexible packaging to meet this demand and has created an advanced material that's fit for the circular economy."

What determines whether 2DPE scales?

Duo says it is in active discussions with additional retailers and converters beyond QVC.

Milestones that will decide whether 2DPE scales beyond a single fulfilment hub:

• Rollouts to further UK and European e-commerce operators
• Third-party certification of recyclability under OPRL or equivalent schemes
• Per-square-metre pricing against incumbent virgin-and-recycled film blends

The Plastic Packaging Tax rate, currently £217.85/t, and modulated EPR fees taking effect from 2026 remain the regulatory floor that decides how commercially valuable any 15-point recycled-content gain is at scale.