The role, innovation and development prospects of paper barrier materials!
1. Strike a balance
Paper as a packaging material is not outstanding in terms of barrier properties, so it needs to undergo further processing, usually adding a barrier coating during papermaking or processing.
One of the key challenges is to find a balance between the required functionality (barrier and strength) and ensure the sustainable lifespan of the existing recycling infrastructure, while meeting all product safety standards. Jenny Vavima, director of product and technology at UPM Specialty Paper, pointed out that this needs to be reasonable in terms of total cost of ownership, which also creates some revenue growth opportunities as consumers prefer fiber-based packaging.
Christopher Wachter, director of flexible wrapping paper at Kohler Paper, believes that plastic composites have strong barrier properties, but not every product has to have this barrier property, so the required functions need to be clearly defined. He also mentioned that the functional problem of the machine needs to be solved, that is, paper without composite material must also pass through the same packaging line as plastic composites. Therefore, it is crucial to jointly define the required functions and choose the right paper or jointly develop a solution.
Eric Valette, director of innovation at Coveris Flexible Business Unit, points out that paper and plastic are completely different materials in terms of physical properties, including differences in properties such as moisture resistance, stretchability, porosity or sealing. These differences are important when designing the best packaging. So switching from plastic to paper isn't just a material change, it's prompting packaging producers to find ways to close the gap and achieve the same functional properties.
2. Supplement or replace plastic packaging
According to our experts, customized solutions are the way forward for every product. They agree that a variety of different packagingmaterials have a role to play, while also emphasizing the advantages of paper.
Both plastic and paper will play an important role in the future, says Vavima - plastic excels in functionality and versatility, while paper has an advantage in sustainability: it is a renewable raw material, used globally, has a good recycling infrastructure, and has the advantages of sustainable development. Sometimes an effective solution may require combining the strengths of both materials. "The chosen material needs to meet the goals of protecting the product. I see many opportunities to increase the use of paper, but ultimately it is up to the brand owner's commitment and choice to drive packaging."
Two main trends have been driving the development of alternative and greener packaging materials: the need to replace materials that are difficult to recycle and to improve the barrier properties of paper. "From Coveris' point of view, it's not about choosing between paper and plastic, but about finding the best, most eco-efficient and best performingpackaging solution for the corresponding product - there are no limits to materials," Valette said.
Wachter sees some limitations of paper, but he is optimistic that paper will play an important role in primary packaging. "Paper is a natural product and it cannot meet all barrier needs. For some purposes, composite packaging will still exist. When choosing a food packaging solution, the focus is always on protecting the contents. There are currently many paper solutions that can be used on existing packaging lines without sacrificing production efficiency. In the global market, many paper-based secondary packaging products in the food industry have already achieved success. Tier 1 packaging, such as primary packaging for chocolate or nuts, is currently being launched on the market. We expect that in the near future, most primary packaging will be made of paper materials. "
3. Pay attention to food safety
Ensuring the safety of food throughout transportation is critical, not only for primary packaging, but also for secondary and tertiary packaging.
During transport and storage, products require special protection against the potential migration of hazardous substances in outer packaging. For example, at Coveris, we are constantly increasing the use of recycled materials in secondary and tertiary packaging, which is a best practice for the environment. But these materials are not suitable for direct contact with food and do not ensure natural barriers (mineral oils MOAH and MOSH) against eg bacteria etc. Therefore, we need to ensure that primary packaging can provide proper barrier properties and prevent the migration of recycled materials and corrugated cardboard used in secondary or tertiary packaging. Valette added.
Regulations on recyclability and food contact in different countries can be challenging, as can the lack of a definition of what paper recyclability means. There is currently no unique way to assess paper recyclability, nor is there a uniform regulation to require it, even in the European Union. Most of the time, packaging designs are rolled out in multiple countries at the same time, and the main challenge is to ensure that the solution meets the recycling requirements of various regions. Valette said.
Valette pointed out that the main challenges faced when developing new barrier concepts are the regulation of product ingredients in direct contact with food in different countries, as well as the individual requirements of large companies and businesses. It is important that the barrier materials and technologies we develop do not affect the recyclability of paper, as this is the main advantage of this material. When it comes to our flexible packaging solutions, we call it 100% paper because only dispersions are used in the production of paper. It achieves barrier properties, but does not contain harmful substances such as PVC, PVDC or traditional composite layers, and direct contact with food is harmless.
Vavema added that recyclability as a greasy and wet food end-of-life solution can be challenging due to the presence of food residues. In these types of applications, composting would be the most viable sustainable end-of-life solution. Non-food applications are relatively easy, although certain regulations (e.g. toys) naturally need to be considered in product design. In addition to this, similar design criteria exist, namely balancing functionality, circularity and financial viability.
I agree that the lack of global recyclability guidelines presents challenges. As the consumption of newspapers, magazines and other printed paper continues to decline, organizations such as 4evergreen are working to create certification systems covering a wide geographic area and are considering developing novel packaging solutions and the changing composition of recycled paper and cardboard streams.
4. Future potential
When asked about the development potential of paper packaging, Mr. Wachter highlighted the further development of the barrier concept. Barrier materials for oxygen, saturated hydrocarbons and aromatic hydrocarbons, and oils have been developed and put on the market, so they can be used to pack dry and greasy foods such as chocolate or cereal, he said.
However, paper packaging is not currently available for liquid products, but they hope to introduce materials with water vapor barrier properties in 2023, which will help address packaging needs for liquid products, such as laundry detergent or pet food. Various market tests are currently underway, and they are further developing dispersions to eliminate barrier layers based on biological and renewable raw materials.
Mr. Valette sees a huge growth opportunity in the paper packaging market. According to their market research, the paper packaging market is expected to grow steadily at an annual growth rate of 3.5%, reaching a market value of $493.50 billion by 2027. Their newly established paper business unit already accounts for 30% of the group's total sales, further confirming this trend.
Finally, Mr. Vavima emphasized the importance of collaboration in achieving the SDGs. He believes that through openness, agility and collaboration with new types of partners, the most important SDGs can be achieved in paper packaging design. He noted that even products with high barrier requirements can be achieved through recyclable solutions and that co-creation of solutions is required as there is no single perfect solution to replace plastics.