The path is basically mapped out. In view of the contribution of packaging material to the increasingly dramatic state of our environment, alternatives are urgently needed. Alternatives that are suitable for a real circular economy - and at the same time fulfil all the basic requirements for packaging. No matter how one assesses the interactions between "society" and "politics": Clearly, this search has become much more intense.
"I myself was amazed at how quickly barrier solutions for fibre packaging came onto the market after the 2019 Packaging Act. When I enquired, the paper industry often said that many solutions had already been developed years ago," says Pacoon Managing Director Peter Désilets.
And it is proving successful. The obvious solution - recyclable packaging made from renewable raw materials - is increasingly finding its way into practical application, as Peter Désilets has noticed: "Now the demand for sustainable solutions has increased significantly and the licensing costs are also making fibre solutions more interesting. This means that previously developed solutions often 'only' need to be finalised. But of course there are also many more new barrier solutions on the market than before."
Major advances in food packaging
This also applies to one of the most sensitive areas in the packaging industry: food packaging. Consumers and legislators alike are wary of new developments when it comes to food compatibility and ensuring best-before dates. Companies such as Wiesbaden-based BMS have already developed solutions for this: Packaging for cheese, sausage or fish that is either made exclusively from fibre material or has an extremely thin plastic barrier. The special thing about this is that the plastic content is low so that the packaging can be disposed of directly in the waste paper cycle.
Psychological component in consumption
This also solves a serious psychological problem. It turns out that many consumers do not separate the individual elements and dispose of them separately. Combinations of recyclable base and plastic lid, for example, are therefore only partially recycled. "The 3-component yoghurt pot has clearly demonstrated the problem. Each component on its own is actually very easy to recycle. However, as a single cup, only one component is usually recycled and the rest is incinerated. Most consumers don't know what to do or are probably too lazy. It is therefore important to either develop components that separate automatically or to make separation unavoidable during handling. There are various ideas on how this can be achieved," says Peter Désilets.
New packaging materials on the horizon
Research and development in this area are far from being at the end of their dynamic. Intensive work is being carried out on the barrier in particular. The goal of replacing plastic components with biodegradable coatings is getting closer and closer. Interesting material candidates are coming into focus: grass, bagasse, hemp and straw, rice straw and bamboo, even seaweed and algae could also replace the last plastic barriers in food packaging. "From our point of view, the aim of every development is always to ensure that the packaging enables the raw materials to be recovered as far as possible during recycling. Not every fibre material is suitable for this and not every barrier behaves in such a way in recycling that the fibre quality is guaranteed. And it is always important to ask where the raw materials come from. Long transport routes make some raw materials unattractive," says Désilets. But despite all these restrictions and factors, Désilets is convinced: "The advantage of fibre materials in general is that recycling exists in virtually all countries and even if the packaging ends up in nature, fibres degrade. If the barrier is still biodegradable, you can at least avoid the littering problem to some extent."
The European Commission is tightening the reins on recycling
It is obvious that the increased awareness on the part of consumers and producers is fuelling this development. Those who package their products in an environmentally friendly way can generate added value for their brand image.
However, regulatory pressure has also increased and will continue to do so. With the Packaging and Packaging Waste Regulation (PPWR), the European Commission has tightened the reins considerably and wants to pave the way for a functioning circular economy.
The packaging regulation, which will soon have to be successively implemented in the EU member states, tightens numerous targets and thus imposes a range of obligations on the packaging industry, manufacturers, retailers and importers. Among other things, new European rules apply for determining the recyclability of packaging. And these are monitored very closely: every single new packaging variant undergoes a special test procedure and must therefore prove its recyclability. A huge effort, no question. But the criteria for the tests are intelligently chosen: It is not simply a matter of determining whether a fibre-based packaging contains no foreign materials or is classed as a so-called 'mono-material'. It may also contain up to 20 to 30 % foreign matter, as long as it does not impair the overall recyclability. In other words, it is worthwhile for the packaging industry to follow the relevant developments very closely or to work on them themselves. "We are currently working on several topics relating to the PPWR: both sales packaging (more B2C) and transport packaging (more B2B) and e-commerce. Each area has specific requirements. Fibre packaging has advantages because the recycling infrastructures already exist in many cases and the use of recyclates has been common practice for decades. Plastic packaging poses the greatest challenges because the infrastructures still need to be established and the target rates for real recyclability ('at scale') and the use of recyclates are high. This is where our many years of experience with innovative fibre packaging naturally comes in handy," explains Désilets.
New perspectives: Fibres for rigid packaging
While excellent solutions already exist for food packaging and new ones are constantly being added, another field is increasingly coming into focus: rigid packaging.
Contrary to the prejudices that still exist, fibre-based materials can also be extremely robust. Accordingly, the development of new technologies in fibre casting is also highly exciting: waste paper and used cardboard are dissolved in water and the remaining suspension is further processed in moulding stations. After drying, an extremely tough and stiff material is created that has a strong cushioning and protective function - and is, of course, 100 per cent recyclable.
In combination with new applications - such as spraying the material - cast fibre applications are currently developing more and more from the area of packaging materials towards an ecological alternative for large packaging or transport and load carriers in logistics. "We are involved in the development of some barrier fibre casting solutions ourselves or are following them very closely. The developments can be seen on several levels: fibre casting or fibre moulding technology on the one hand and barrier applications on the other. We are also working hard to simplify mould production. We are even seeing technical advances in labelling/branding in applications such as the new Flora packaging. So an old, 'unspectacular' technology such as fibre casting is currently experiencing a renaissance. And even liquid packaging is already feasible," says Désilets: "We find this very exciting."
New technology, new processes: European trade fair Fachpack cooperates with Pacoon
The exciting developments in production and services are naturally also reflected in the industry's trade fair, Fachpack (Nuremberg, 24-26 September 2024). The use of fibre-based packaging is not just a cross-sectional topic at the event - this year, Pacoon is cooperating with the organiser to create its own pavilion on all three days of the trade fair: "Fachpack Alternative Packaging Solutions in Cooperation with Solpack 5.0". Pacoon has a lot planned during the trade fair, as Désilets announces: "We have put together a programme that focuses on reusable packaging (Day 1) and fibre packaging (Day 2). On day 3, we have planned cross-material recycling topics. The pavilion is already fully booked by exhibitors and interest has been high. In Hall 3, we will guide visitors through the programme on all three days and aim to inform and inspire them. We will shortly be presenting the programme and the speakers together with the Fachpack team.