Syntegon-BillerudKorsnäs’ paper pod partnership pioneers single-use plastic replacement

07 May 2020 --- Syntegon Technology and BillerudKorsnäs have launched a joint packaging system for uniquely shaped and right-sized paper packaging pods. Combining Syntegon Technology’s manufacturing equipment and BillerudKorsnäs’ configuration of its 3D formable FibreForm paper, the customizable Shaped Paper Pods offer a thin barrier plastic-alternative solution for dry, chunky or viscous foods and cosmetics. The partnership aims to have the first production machines running in 2021 and is currently working with several international brands on the development of the paper pods.

“We achieved a perfect match of technology and material for scalable packaging solutions, which creates a unique sensory experience for brand and customer interactions,” says Matthias Klauser, Sustainability Expert at Syntegon Technology.

The new TPU paper form, fill and seal machine forms environmentally-friendly Shaped Paper Pods with a filling volume of just a few and up to 100 milliliters. The FibreForm paper is shaped by air pressure and embossed by press force. Using heat-sealing technology, the pods can be sealed with any heat-sealable lidding materials and barriers can be completely customized to customer needs.The TPU paper form, fill and seal machine shapes paper pods with a filling volume of 10-100 ml.

A pearl in the shift to renewable
To showcase the possibilities and the flexibility of the system, Syntegon Technology and BillerudKorsnäs previously presented the elaborate packaging concept “Pearl.” Now, shapes of any kind can be formed from the FibreForm paper for product samples, inserts, refills, portion packs and disposable packaging.

“The Shaped Paper Pods system [enables] manufacturers to experiment with different shapes, geometries and materials. The technology has been improved [from “Pearl” stage] to react quickly to customers’ interest in realizing shaped paper pods. This includes additional technical features as well as fine-tuning and process optimization,” Nicole König, Product Communication at Syntegon Technology tells PackagingInsights.

The Shaped Paper Pod system is suitable for individual portion packs and products conventionally packed in blisters.Margarine packed in paper
Shaped Paper Pod applications include spreads, margarine, biscuits or Advent calendars in paper trays. The TPU paper forming machine offers manufacturers a range of filling and sealing systems for more environmentally-sustainable packaging at an output of up to 15,000 pods per hour.

“FibreForm is a natural alternative where plastic has been the norm. Allowing for up to ten times deeper embossing than regular paper, resulting in 3D effects that make an impact,” adds Simon Johansson, Project Manager at BillerudKorsnäs, Sweden.

Syntegon Technology calculations find that Shaped Paper Pods have an approximately 23 percent lower carbon footprint compared to conventional composite material packaging. König offers a reminder that packaging comparisons must be considered on a case-by-case basis.

Plastic replacement challenges
Shaped Paper Pods do not necessarily offer a one-to-one replacement of an existing polymer packaging. According to König, this was the biggest barrier the partnership overcame in the development of the pod manufacturing system.Shaped Paper Pods boast unique embossing and shape, e.g. for in-store campaigns or product demonstrations at an event.

“Due to the different properties of paper materials, such as the stretch of the material, we needed to rethink and adapt some shapes. Some products had to be packed in a new, unconventional way.”

“The extensive collaboration with partners, including material producers, brand owners and design agencies, was fruitful and showed us just what was possible. We defined a process to create tailor-made Shaped Paper Pods and reduced the time it takes from initial ideas to prototypes,” König explains.

Now live: The Virtual Show 2020
Syntegon Technology is currently demonstrating its latest solutions at the Virtual Show 2020 from May 7-13. In addition to Shaped Paper Pods, the company is presenting MIRA (Machine Intelligence Reporting & Analytics) for the first time.

Shaped Paper Pods reportedly have a 23 percent lower carbon footprint compared to conventional composite material packaging.MIRA is capable of identifying machinery component failure up to six weeks in advance, preventing downtime without intervening with machine controls. As the COVID-19 pandemic continues, Syntegon Technology is also offering its Remote Services for customers needing assistance with machine settings or troubleshooting.

Following the introduction of the Syntegon Technology corporate brand at the beginning of the year, the company is also unveiling its new product design for the first time at the event.

The process and packaging technology specialist reported stable business performance in 2019. Sales increased to €1.33 billion (2018: €1.28 billion) and new orders also rose slightly. In the wake of the coronavirus crisis, the systems supplier to the pharmaceutical and food industries reports increased demand in its services business.

By Joshua Poole