Building barriers: Packaging leaders pioneer responsible coatings for fiber-based circular economy

05 Jul 2023 --- Consumer packaging companies are experiencing end-market pressure to reduce plastic amid demands for more environmentally sustainable – often paper-based – solutions. This mega-trend is spurring innovation in barrier coatings that support circularity. 

Notably, Mondi is expanding its range of medium, high and very high barrier paper-based packaging – FunctionalBarrier Paper – to support customers with more environmentally sustainable packaging solutions. 

“Our innovative range of barrier packaging ensures excellent product protection, fulfilling the requirements of each specific product by using different technologies to tailor fit-for-purpose packaging. The full barrier packaging range is designed for recycling and can substitute unrecyclable plastic laminates and aluminum-based packaging,” Fabio Peyer, head of sustainability for Flexible Packaging at Mondi, tells Packaging Insights.

Meanwhile, Stora Enso offers barrier solutions that enhance the protective properties of fiber-based materials to guarantee safety and functionality for a growing variety of applications.

“Barriers are at the center of our innovation activities, and we continuously work to reduce fossil-based plastic and enhance recyclability,” Ville Ribu, technical product manager for Barriers at the supplier, tells us.

Mondi's aluminum-free coffee packaging solution.Scaling capacity 
Mondi recently expanded its FunctionalBarrier Paper range through investments in scaling up its product capacity on production lines, new technology and equipment. 

“For instance, we have significant investments in building a new extrusion coater and rebuilding an existing coater to provide high-quality barrier coating for very high barrier packaging,” explains Peyer.

“We are constantly improving our packaging quality and achieving the required barrier level to suit product and customer needs.” 

The packaging leader’s current product portfolio includes various solutions ranging from medium to high and very high barrier paper-based packaging, containing different characteristics and levels of protection for the product. 

Meanwhile, Stora Enso has improved its barriers by making them lighter, thinner and more circular.

“Our new dispersion coating technology improves barrier board recyclability while offering the necessary functionality required for food packaging – or packaging more broadly,” says Ribu.

“This means that materials can be efficiently separated in the recycling process, and more fibers can be reused in new fiber-based materials, which helps to improve our circular economy.” 

Plastic-reduced barriers 
Mondi’s FunctionalBarrier Packaging range ensures fit-for-purpose product protection while being designed for recycling in paper streams across Europe. 

“The barrier packaging solutions offer an alternative to plastic laminates and multimaterial aluminum-based packaging and are made using responsibly sourced base material. Our general approach is to use paper where possible, plastic when useful and our FunctionalBarrier Paper range is a perfect example of this,” says Peyer.

Stora Enso’s Trayforma BarrPeel.Stora Enso uses technologies like dispersion coating and its proprietary UltraThinPE Tec, which have enabled such improved recyclability and barrier thinness.

“Both of these innovations reduce the amount of plastic in the package. We also feature a renewable barrier solution and a compostable coating in our offering,” says Ribu. 

Customer and policy demands 
The demand for more responsible packaging solutions is increasing overall throughout the packaging industry, finds Mondi. 

“Our latest addition to our product portfolio, FunctionalBarrier Paper Ultimate offering high-barrier protection, shows positive acceptance amongst customers and end-consumers. Trial results show that the paper solution is widely accepted and even preferred over unrecyclable aluminum and plastic-based alternatives,” highlights Peyer.

Stora Enso’s Ribu adds: “We see a clear shift in many areas, from fully fossil-based plastic items to more sustainable solutions like paper and paperboard. Here opposition to plastic is a real driver. This reaches from most common application areas like liquid cartons and cups to more specialized areas like trays and flexible packaging.”

He explains that solutions are also being “finetuned” due to new regulations like the EU’s Single Use Plastics Directive and Packaging and Packaging Waste Directive.

“This regulation can lead to greater differences in packaging applications: for example, demand for the true minimization of packaging where very short shelf life is required versus demand for highly sophisticated solutions for more challenging applications like replacing aluminum foil.”

By Natalie Schwertheim