Coveris aims to revolutionize European food market with recyclable high-barrier paper formats

19 Oct 2021 --- Coveris is converting a “potentially revolutionary” new paper into flexible packaging for dry foods to meet growing demand for recyclable alternatives to plastic-based solutions. Notably, the material’s barrier properties are competitive with plastic, mitigating food waste.

PackagingInsights discusses the PaperBarrier Seal project’s technicalities with Bernhard Mumelter, group innovation manager at Coveris, who is responsible for the material’s coating technology, and Christian Kolarik, president for flexibles at Coveris.

We are also joined by Markus Poelzl, managing director for marketing and sales at Brigl & Bergmeister. Brigl & Bergmeister is the inventor of the barrier-base paper. Franz Rappold from Rafra Consulting, who represents the paper supplier’s shareholders, also shares some insights.

Innovation in fiber-based solutions is booming as brands explore plastic waste escape routes and new connections with the enlarging eco-conscious consumer base. According to Innova Market Insights, 72% of global consumers recognize paper as having “good” or “exceptional” recyclability.

PaperBarrier Seal’s product development took over two years and involved extensive validation and testing, requiring a “close and transparent” partnership between Coveris and Brigl & Bergmeister. The solution debuted at FachPack 2021, with the partners agreeing the project’s results have exceeded their expectations and could “revolutionize the food market in Europe.”

A new life for paper
The project’s end goal was to give paper “a different nature,” explains Mumelter, “offering properties a fiber-based solution – by its nature – cannot offer, providing barriers against oxygen, moisture, and mineral oils.”

“How did we overcome these challenges? First of all, by designing the paper in the right way to enable good palpability, a smooth surface, and by defining the right coating for the barrier properties.”

“We have developed three basic versions of the PaperBarrier Seal. One version is designed for moisture barrier applications – we achieved a moisture barrier in a level below 10 grams in standard temperature and humidity conditions, and excellent behavior in tropical conditions below 50 grams.”Coveris and Brigl & Bergmeister believe the PaperBarrier Seal could “revolutionize the food market in Europe.”

“Meanwhile, the oxygen barrier solution is mainly designed for oxygen, grease and mineral oil barrier.”

The two barriers can be combined for what Mumelter refers to as the “All Solution,” providing oxygen, moisture and mineral oil barriers and grease resistance.

Dry foods and beyond
The PaperBarrier Seal’s initial target markets are dry foods, including noodles, rice, pasta, cereals and confectionery. “We have to launch this paper on the market and create attention,” says Kolarik. “We will learn over time which other applications are suitable.” 

“The combination of wet and greasy can be a very complex application for packaging,” adds Rappold, “but also here the PaperBarrier Seal is an adequate solution.” The partners further hint at the possibility of personal and homecare applications.

“The solution’s potential is high. We have to learn more about it,” reemphasizes Kolarik. “Our customers are always looking for the best barrier, but this is not always the right barrier, so we must learn with our customers where to apply this solution.”

Consumers are not typically accustomed to the concept of paper-based packaging matching plastic on shelf life. According to Innova Market Insights, 56% of global consumers believe paper-based packaging provides average or below average product protection.

Making economic sense
The development team was also aware its plastic-replacement material must deliver on runnability and cost-effectiveness – not only recyclability.PaperBarrier Seal’s barrier properties are competitive with plastic, mitigating food waste.

“We must not forget to maintain the material’s runnability because we are talking paper versus traditionally plastic-based materials,” highlights Mumelter. “But we have been able, with the nature of the paper, and the way it is designed, to keep the runnability on standard packaging equipment. So the solution’s sustainability and formability are excellent.”

The new paper has been tested on standard VFFS and HFFS packaging lines and achieved a production speed of up to 200 products per minute.

Moreover, Mumelter confirms the paper is recyclable through household paper streams. “There is no international norm on [recyclability] yet, but it [PaperBarrier Seal] was tested according to the method which will most probably be the recyclability method [in future],” he says.

“Of course, we also need to meet a similar price point [to plastic] because otherwise it will be a promotional greenwashing initiative and never a stock-keeping unit, as it has to make economic sense,” adds Poelzl. “It was tough to achieve this level of cost-effectiveness.”

Competitive shelf life
The PaperBarrier Seal reportedly outperforms current paper solutions on barrier properties. However, a key issue for the development team is understanding how the packaging’s shelf life differs across different flexibility levels and mechanical behaviors.

“The shelf life will also be determined by the way the material is used,” notes Mumelter. “Often, with these kinds of barrier-extended properties, harsh packaging conditions need to be challenged and tested, but as far as we have seen, this solution is outperforming current paper solutions. We have defined barrier values, but mechanical treatments still need to be evaluated case by case.”

“We know customers will not compromise on shelf life,” adds Kolarik, “so whatever we offer needs to fulfill their expectations, which are similar to what is available today [with plastic-based solutions].”According to Innova Market Insights, 72% of global consumers believe paper has “good” or “exceptional” recyclability.

“The [shelf life] range is roughly between 15 minutes for fast food and up to two years for other applications, like rice. It depends on how the product is reacting under certain conditions,” reiterates Rappold.

Although the PaperBarrier Seal is competitive with plastic on barrier properties, interestingly, 46% of global consumers would accept decreased product shelf life in return for more environmentally sustainable packaging, according to Innova Market Insights.

European launch, global ambitions
PaperBarrier Seal formats are now available in Europe, while global availability will be discussed at a later stage.

“As we say, we need to define the project very carefully because it’s a brand new material,” stresses Mumelter.

“We are already in contact with big FMCGs, and they sell globally, so it would be effectively a global project if it takes off,” adds Poelzl.

PackagingInsights also recently spoke to Will Mercer, business unit R&D director at Coveris, about the company’s other circular economy solutions, namely its MonoFlex monomaterials range, Duralite R Recycled shrink film, wash-off labels and linerless label punnets.

By Joshua Poole