paper packaging should provide functionality while facilitating recycling

One of the key elements of the circular economy is recycling and its role in keeping materials in the production cycle. Unfortunately, large amounts of packaging produced today cannot be recycled.

As part of responsible product design, we are committed to continuously improving the environmental performance and functionality of barrier paper packaging. Together with our R&D partner DELSCI we are developing the next generation of barrier paper packaging that is both functional and easily recyclable.

easily recyclable materials reduce waste and pollution 

A demanding part of the recycling process is sorting; separating different layers as each type of material requires specific process conditions to be recycled. This is especially challenging for the flexible packaging sector where layers are often added to give packaging additional functionality. This type of packaging is called composite packaging. Composite packaging is made of two or more layers of different materials that cannot be separated by hand and form a single integral unit.

Many countries do not have the necessary recycling systems and processes in place to recycle complex laminates. Therefore, composite packaging is often not recycled. 

While composite packaging has taken over the industry with attractive features that protect packaged products and increases their shelf life, it has also created an obstacle in our movement toward the circular economy. 

base papers must work in unison with barriers to facilitate recycling 

Paper alone cannot provide sufficient functionality for many packaging applications. Barriers are necessary to provide the required performance against oxygen, aroma, fat, and water vapor. Fiber-based packaging is often laminated with other materials such as plastic or aluminum. These barriers make recycling difficult or impossible and this packaging often ends up in incineration or landfills. Therefore, the optimal solution is barrier paper, which will offer the required functional benefits, without negatively affecting the recyclability of the packaging.

It is therefore essential to not only produce a great base paper but also apply a functional coating that allows the final product to be easily recycled. Such paper packaging facilitates recycling and provides options for companies looking to substitute their multi-material packaging options.

building a better base and a better barrier

Thankfully, our R&D specialists and paper technologists are innovating to balance shelf life, product safety, and environmental impact. Our goal is to develop packaging that eliminates the need for material separation, increasing the likelihood that the packaging will be recycled.

As an alternative to composite packaging, non-composite packaging has emerged as a revolutionary logical and ecological solution. A non-composite is defined in different ways in different countries. The 95/5 rule is currently the strictest definition. This means that only 5% of the total packaging can consist of barriers and inks. The barrier cannot be a separate layer but must be intertwined with the base paper. In many European countries, the categorization of a non-composite material is between 50/50 and 85/15 and the USA follows the 85/15 threshold.

One way to meet these definitions is to make the base material thicker so that the barrier, as a percentage of the whole, is less. We believe this is not the right way to do things. It goes against our larger objective of reducing packaging waste and creating sustainable solutions. 

The better performance a base paper has, the less coating material it needs to be functional. This is why it is essential that packaging base papers be high-quality and be designed specifically for different use cases.

the challenges of non-composite barrier paper packaging

Developing non-composite paper packaging with functional barriers is no simple task, there are many factors that need to be considered to make the packaging both sustainable and functional. Each layer of multi-material packaging has a specific purpose that now needs to be met by a non-composite material, keeping the desired individual properties.

Some of the key challenges include reaching adhesion, printability, processability, yield, heat-sealability, transparency, and food contact compliance comparable to those of multi-materials. Our R&D department develops specialty paper by considering the required mechanical properties and barrier functions while maintaining the excellent ecological profile of paper, and processability on existing converting and packaging lines.

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Developing recyclable and functional packaging is no easy feat but we are embracing the challenge. This is how we revolutionize paper.

about our R&D partner DELSCI

DELSCI is a research organization that develops eco-conscious paper for food and consumer goods packaging. They are a team of scientists and technologists on a mission to empower people to consume responsibly. This means replacing plastic (wherever possible) with functional paper that works harder than ever before and helps protect the environment.

Make the switch to function and recyclable paper packaging

We would love to hear from you!

Herwig.Kirchberger@delsci.com I +43 7229 776-552