KEEPING IT CIRCULAR
How recycled fibre, refreshed with virgin, can travel the loop up to 25 times
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3 Editorial Elisabeth Skoda
4 MM Group Recycled fibre or virgin – which is best?
Navigating the PPWR – a practical guide
Oxywise Cutting costs and carbon footprint: The sustainability case for generating nitrogen in-house
Sustainable Packaging Summit preview Turning ambition into action
Drinks and liquid food Spotlight on the evolving markets
30 In Conversation With… Packsys presents noSho – the cap-free, plastic-saving shoulderless tube
32 In Conversation With… An insider’s guide to Smurfit Westrock’s first year as a combined company
34 Circular packaging A matter of material and machines
37 Innovation centre Inside Mondi FlexStudios – and its vision for circular packaging
40 Paper vs plastics Bringing nuance to the debate
46 In Conversation With… FluoZero: YutoEco’s PFAS-free solution to oil resistance in moulded fibre packaging
48 In Conversation With… How sustainable chemistry drives the circular economy for packaging
50 In Conversation With… A look inside Mondi’s acquisition of Schumacher Packaging
52 In Conversation With… Digitalization and standardization: the keys to regulatory compliance?
55 The Spotlight Coveris & ReCover: driving circularity in a changing legislative landscape
57 The Spotlight Unlocking the future of packaging with fibre-based materials
59 drinktec news What to look out for at the show
61 Labelexpo interview Trends and innovation –from sustainability to automation
64 Labelexpo press releases Innovation preview
Welcome to this special edition of Packaging Europe magazine.
As in previous years, while I’m writing the editorial for the autumn edition of Packaging Europe, large parts of the Northern Hemisphere are witnessing the effects of climate change first hand, with droughts, floods and wildfires now an ever-present feature of summer.
While it may appear that sustainability is taking a back seat on the political stage, this serves as a reminder of its importance. There has been some backtracking on sustainability goals, but many industry players across the value chain are still working hard to improve packaging sustainability, as exemplified by our Sustainability Awards, which, as in previous years, have received a wide
EDITORIAL
range of impressive submissions. The winners again will be unveiled at this year’s Sustainable Packaging Summit, which takes place over three days, from November 10th to 12th, 2025 in Utrecht in the Netherlands.
As we head into autumn, the industry’s events calendar is busy with big shows such as FachPack, Labelexpo Europe, drinktec, K 2025 and of course our own Sustainable Packaging Summit.
This issue is jam-packed with content that highlights the industry’s efforts to boost sustainability. In our cover story, the experts from MM Group discuss virgin and recycled fibre and how, based on material agnosticism, the company supports customers in choosing the right option for their individual sustainability goals.
The PPWR continues to raise many questions that need answering.
Experts Anna Perlina and Renata Daudt talk us through a six-step process to tackle the regulatory requirements. Anna and Renata are content partners of this year’s Sustainable Packaging Summit. You can read an interview with two further speakers, Willemijn Peeters and Dagny Tucker, and find out more about what to expect at the event within the pages of this magazine.
With Labelexpo Europe moving to Barcelona, we explore sustainable developments in the sector and take a closer look at what visitors can expect to see at the show. In the context of drinktec in Munich, we take a closer look at the evolving beverage packaging market.
Elsewhere, we report from our visit to Mondi’s new, cutting edge FlexStudios customer experience centre, and hear leading industry voices on the ever-relevant topic of whether paper or plastic makes a better, more sustainable packaging material.
We hope you enjoy this edition of Packaging Europe magazine, and we look forward to seeing many of you at the Sustainable Packaging Summit in Utrecht!
Elisabeth Skoda · Editor at large
Cartonboard made of 100% recycled fibres can deliver the surface qualities brand owners need in multiple segments, including dry food.
RECYCLED FIBRE OR VIRGIN – WHICH IS BEST?
MATERIAL AGNOSTICISM IN PRACTICE:
MM GROUP’S APPROACH TO FIBRE SELECTION
Katja Tuomola (Head of Group Sustainability & Marketing Communications), Tom Kratochwill (CSO for Board & Liner at MM Board & Paper) and Andreas Koppitz (CEO for Pharma & Healthcare Packaging at MM Packaging) discuss with Elisabeth Skoda how the two options stack up across key metrics such as performance, sustainability and cost-effectiveness, and explain how the company helps its customers make the right decision according to individual goals.
Elisabeth Skoda: Katja, starting out at a broad level, what are the advantages of recycled and virgin fibre along different metrics, such as sustainability, functionality and look?
Katja Tuomola: In our production, recycled fibre plays an important role in conserving resources because it uses less energy, water, and wood. By recycling valuable fibres, we simultaneously reduce waste to landfill. Recycled fibres can contribute to a lower carbon footprint, which is valuable in view of climate goals. On the other hand, virgin fibre offers exceptional strength, purity, uniformity and visual appeal, which is relevant for sensitive packaging applications that have demanding performance parameters and require a flawless finish, for example in the food or pharma industries. Both recycled and virgin fibres are recyclable and thus contribute to packaging solutions that support circularity. Our focus is on selecting the material that best fits the specific functional, regulatory and environmental profile required by each customer’s use case.
ES: How has the conversation around fibre selection evolved with increasing regulatory pressure?
KT: Regulations like the Packaging and Packaging Waste Regulation (PPWR) have brought the recyclability and overall environmental impact of packaging materials into sharper focus. Fibre selection is now part of a broader strategic dialogue, where customers aim for solutions that support their environmental goals while remaining adaptable to future developments. There is also growing interest in minimizing plastic components and ensuring that packaging design contributes to a more circular economy, alongside meeting performance and safety criteria. Packaging material choices are also more driven by extended producer responsibility (EPR) fees making fibre materials more attractive. Furthermore, the EU Deforestation Regulation (EUDR) offers a robust way for us to show where our virgin fibres are coming from.
“Our focus is on selecting the material that best fits the specific functional, regulatory and environmental profile required by each customer’s use case.”
Katja Tuomola (Head of Group Sustainability & Marketing Communications)
ES: Tom, are there any particular innovations that have made recycled fibre a viable option for a wider range of applications?
Tom Kratochwill: Advances in processing technology have enhanced the suitability of recycled fibre for demanding applications. Our modern fibre treatment lines at MM enable precise cleaning, sorting and preparation, which lets us produce recycled fibre grades with a high level of consistency, while using fewer raw materials and less water and energy. There is also the option to refresh recycled fibre with virgin fibre, which allows it to travel the loop up to 25 times. Innovations in surface treatment and coatings have further improved the printability and converting properties of these grades, so they perform well even in technically challenging applications. For example, our MCM® ECO board consists of 100% recycled fibres and has surface qualities that meet the expectations of brand owners in different segments. Further developments in barrier technologies have allowed recycled fibre to be used in food contact packaging when combined with a thin layer of virgin cartonboard or appropriate coatings. We also work closely with research institutes and industry partners to explore how fibre structure can be preserved over multiple recycling loops. This work reinforces confidence that recycled material can meet technical requirements in areas that demand reliability and high quality, such as food and personal care packaging. These combined efforts continue to extend the possibilities for recycled fibre applications.
ES: In which applications do you see recycled fibre outperforming virgin fibre in both performance and cost-effectiveness?
TK: Recycled fibre is particularly well suited to sectors where packaging needs to balance reliable performance with efficient use of resources. This includes
packaging for household products, frozen foods, and many non-food consumer goods. In these areas, white lined chipboard (WLC) offers the required strength, printability and barrier properties at very attractive costs and high performance on the converting and packaging lines.
ES: How does MM Goup ensure consistent quality and supply of recycled fibre grades across markets with varied collection and recycling infrastructures?
TK: We achieve consistency through a combination of strategic fibre sourcing and advanced processing technologies. In terms of sourcing, we buy recycled paper grades that have the qualities we need for our WLC portfolio. We select partners who are industry experts in fibre collection across Europe and beyond, so that our recycled fibre purchase comes with the needed certifications, such as FSC and PEFC. Through technology, we are at the same time reducing our overall fibre consumption with process innovations. By using internal starch additives, for example, we can increase bonding strength between fibres, improving tensile strength and stiffness. With surface additions we can enhance printability, barrier properties and surface strength.
ES: Andreas, I’d like to look at applications where virgin fibre is more fit for purpose, for example in pharmaceutical packaging. What makes virgin fibre most suitable in that area?
Andreas Koppitz: Although recycled board is an excellent option in many packaging sectors, the pharmaceutical industry requires virgin fibre for most secondary packaging applications. Pharmaceutical products are packed in small folding cartons. These cartons require high stiffness and precision to
“Recycled fibre is particularly well suited to sectors where packaging needs to balance reliable performance with efficient use of resources. This includes packaging for household products, frozen foods, and many non-food consumer goods.”
Tom Kratochwill (CSO for Board & Liner at MM Board & Paper)
“In general, the pharmaceutical industry faces strict regulatory requirements and logistical demands that virgin board’s mechanical properties are better suited to provide.”
Andreas Koppitz (CEO for Pharma & Healthcare Packaging at MM Packaging)
perform correctly on high-speed packing lines. In addition to the medicine itself, the packing process integrates multiple internal components like leaflets, blisters, and fitments into the folding carton – which therefore has to maintain its shape perfectly from start to finish.
As packaging suppliers, we understand the critical need for fast and efficient packaging solutions. In pharma, where timely supply is vital, using virgin board – for example in applications like topload cartons for GLP1 injectors – ensures reliable performance on high-speed lines, minimizing downtime and supporting quick time-to-market. Additionally, regulatory requirements such as Braille marking – governed by specific ISO standards on dot height – and serialization demand surface quality and consistency that virgin cartonboard’s long-fibre structure provides. These many small but vital factors tip the balance toward premium virgin boards like GC2 ALASKA® STRONG and ALASKA® PLUS, with occasional use of GC1 ALASKA® BRIGHT, to ensure packaging meets the strictest standards in quality and performance.
ES: How do regulatory or hygiene requirements shape the choice of virgin materials?
AK: From a regulatory perspective, long-fibre virgin GC2 board grades offer the material properties needed for precise Braille embossing and high-contrast inkjet and laser printing of serialization markings. Patient safety and regulatory compliance depend on the clear communication of this information.
Sensitive pharmaceutical products like vaccines or autoinjectors are delivered via cold chain logistics. For demanding transport and storage conditions, virgin GC2 board generally performs better due to excellent moisture resistance and the structural integrity of long fibres. This helps prevent packaging degradation such as warping or brittleness under low temperatures and humidity changes. Additionally, virgin board ensures higher purity, minimizing contamination risks.
In general, the pharmaceutical industry faces strict regulatory requirements and logistical demands that virgin board’s mechanical properties are better suited to provide.
ES: How do you balance sustainability and the high performance requirements of pharmaceutical packaging?
AK: Balancing sustainability with uncompromising performance is of central importance for us. Our product development approach combines smarter material choices that reduce environmental impact – without sacrificing high standards for stiffness, purity, and regulatory compliance.
For example, we are engaging with our US customers to demonstrate how GC2 folding boxboard (FBB) allows for reducing grammage while delivering per
formance equivalent to heavier solid bleached sulfate (SBS) boards commonly used in North America. At scale, FBB uses less material without compromising on the pharma industry’s need for rigidity and functionality – and it also helps reduce production energy, waste, and transport emissions.
Our goal is to show stakeholders that packaging performance and environmental responsibility is not an either-or choice. We help our pharmaceutical customers make decisions that are good for both patients and the planet.
ES: In summary, how does MM’s approach of material agnosticism help customers navigate complex choices without compromising on performance or compliance?
KT: When customers or other stakeholders want a neutral view on what material is best for their application, they are welcome to come to MM. We are the only European company that can provide them with this unbiased perspective. All our manufacturing data, both for recycled and virgin fibre, has been audited and third party verified. Our multipurpose portfolio gives the customer plenty of choice, and we help to make the right choice for them. Our relationship will grow and be strengthened post-sale when we allow material neutrality to steer each project to the right fibre-based product that addresses performance, compliance and environmental responsibility. All along the buyer’s journey, our commercial and technical teams accompany customers to assess and implement the best
Using virgin board – for example in applications like topload cartons for GLP1 injectors – ensures reliable performance on high-speed lines, minimizing downtime and supporting quick time-to-market.
INNOVATIONS IN LABEL SUSTAINABILITY
What are some of the innovations driving sustainability in the labelling space? How can labels boost the sustainability performance of packaging, and how are they currently being utilized to increase circularity? In this article we take a closer look at how label design, adhesive technologies and end-of-life considerations can all play a part.
The role of the label in packaging circularity
One of the ways labelling can improve packaging sustainability is through its role in packaging circularity. In February this year, brand director Tim Sykes spoke with Nataliya Malhanova of Avery Dennison, Sergio Fregoni from IDEO and RecyClass’s Augusto Bruno about technical recyclability requirements for labels and their integration into product design.
Malhanova stated that for years, we’ve lived in a world where “the only request for a label was to stick well and look good”. She added that in the last decade, Avery Dennison has transformed its portfolio, aiming to meet
greater needs for circularity. Malhanova gave the example of ensuring clean removal from different packaging types like PET or HDPE, following the RecyClass guidelines.
Sometimes, a legislative push can be a catalyst for innovation in the label space. Regarding the Packaging and Packaging Waste Regulation (PPWR), Malhanova believes it created an emergency for all packaging industry players to come up with solutions. Avery Dennison had stringent requirements for rigid plastic recycling when it came to label design, which “didn’t make sense” when the company looked at label usage throughout
its lifetime. As a result, Malhanova said the company has worked with RecyClass to include friction as an important element in label removal, rather than its wash-off properties.
When designing packaging, it’s also important for brands to consider the design of their labels and sleeves. Towards the end of 2024, Victoria Hattersley asked representatives from CCL Label and DTM Print about the main considerations and the impact the wrong choice could have.
Marika Knorr, head of Sustainability and Communication at CCL Label, noted that floatable sleeves for PET bottles and other containers are on the rise, with it becoming the mainstream alternative to PET-G sleeves that are ‘detrimental to recycling and on the red list’ of the RecyClass Design for Recycling guidelines.
Considering a label’s end-of-life, Knorr said that for polypropylene (PP) labels – used for a wide variety of plastic packaging – both mechanical and chemical recycled options are in high demand. She stated that this was also true for biobased materials and recycled content that has a clear connection to sustainability, citing ocean-bound plastic that is reused in packaging components.
How can adhesive label technologies improve sustainability?
In a report on this year’s Labelexpo Europe, strategic director Andy Thomas-Emans highlighted that the circular economy requires packaging materials that can be cleanly separated and returned to the same point
in the value chain after processing. When referring to labels, he gave the example of the label adhesive removing ‘cleanly’ from the container. He added that the label also needs to provide information on the recyclability of each component of the container or pack, and will also “provide the mechanism to activate post-consumer automatic materials sorting systems via machine-readable codes, as projected in the Holy Grail programme”.
Bearing this in mind, what role can adhesives play in improving the sustainability of labels? As part of our ‘In Conversation With…’ series, Sabine Pietka, global marketing manager Beverage at H.B. Fuller, explained last year how the company’s water-based adhesive technology aims to transform the beverage sector by addressing operational efficiency and environmental sustainability.
She observed that traditional labels on reusable glass bottles pose challenges such as difficulty in removal, residue buildup, and reliance on harsh cleaning methods, which are the main cost drivers and “responsible for considerable environmental impact”. Pietka stated that water-based adhesive technology offers environmental and operational benefits such as reduced water and energy usage during bottle washing, lowering costs and impact.
She added that using single adhesives for various label types simplifies processes, reducing errors and complexity, and that the labelling technology is “borax- and zinc-free, making it safer for operators and better for the environment. Certified to have no negative impact on wastewater treatment, it integrates seamlessly into sustainable production processes.”
In July this year, CCL Label announced its EcoShear adhesive label solution for one-way glass recycling, said to reduce label contamination to 2% and reduce landfill glass waste to 1.5kg per tonne. The new label also aims to reduce waste and contamination, contributing to lower energy consumption, and has a “guarantee for easy recycling at the end of life”.
The power of smart labels
Another area where labelling could potentially boost packaging sustainability is through the use of smart labels. One example is How2Recycle’s How2Recycle Plus label, which features The Recycling Partnership’s Recycle Check QR code and seeks to pave the way for real-time local recycling and disposal instructions. When How2Recycle members opt to adopt the new label, it allows consumers to scan the QR code, enter a zip code or allow location permissions and receive a clear ‘yes or no’ answer on whether a material is accepted for recycling in their community.
Launched in January this year, the label and QR code draw from The Partnership’s National Recycling Database, said to include acceptance data across more than 9,000 unique community recycling programs, representing 99% of the U.S. population. The Partnership adds that “nearly 84% of Americans” recognize the label.
In the same month, Giesecke+Devrient unveiled its reusable, ‘ultra-thin’ G+D Smart Label which embeds Internet of Things (IoT) features into a package and enables location tracking, tamper protection, proof of delivery, and more. Developed alongside hardware partner Sensos, the label is designed to track parcel delivery and shipping, assist in fleet management and monitor the movement of luxury goods.
Sustainable labels on show
If you would like to find out more about sustainable labelling innovation, make sure to visit Labelexpo Europe 2025 in Barcelona from September 16th to 19th at Fira Gran Via in Barcelona in Spain. The event, billed as the world’s “biggest exhibition dedicated to label, flexible packaging, folding carton print and converting technology” will offer live demonstrations, showcase technologies as well as keynotes and master classes on topics such as the PPWR and AI.
NAVIGATING THE PPWR –A PRACTICAL GUIDE
In June, we invited packaging consultants Anna Perlina of Integrity Solutions and Renata Daudt from Awen Packaging Consulting to share their insights on how to navigate the EU’s Packaging and Packaging Waste Regulations and how to take action to meet milestones and requirements in a well-attended webinar. This article outlines some of the key takeaways from the event.
The webinar started with a couple of audience polls. We asked our audience two questions to get a snapshot of where the industry stands with regards to PPWR readiness.
Polll 1: What’s the biggest challenge the industry is facing in terms of EU PPWR?
packaging change in the EU needs to take into consideration the impact of PPWR requirements up to 2040.
“For businesses and the packaging industry in general this means that all packaging strategies and changes should consider the impact of PPWR requirements. A clear vision is needed to not waste time and resources or arrive at the suboptimal outcome.”
Step 1: Interpreting the PPWR according to your context
Renata Daudt reminded us that the PPWR came into force in February 2025, with a transition period until August 2026, at which point it becomes effective. Companies then have until 2030 to align with the regulation, especially around key targets in recyclability and reducing materials. Recyclability thresholds might still be revised depending on evolving technology.
“What is the penalty for not doing anything? You cannot have your packaging on the EU market,” she said.
Poll 2: Where do you think the industry stands in terms of EU PPWR readiness?
From interpreting legal obligations to implementing packaging changes, the speakers outlined a six-step roadmap designed to help stakeholders across production, distribution, and retail understand, prepare for, and meet the PPWR milestones on time. Anna Perlina started by highlighting the fact that the PPWR sets out minimum requirements for packaging sold across EU markets and that as of now, every packaging strategy and every
Businesses need to interpret what this regulation means specifically for their packaging – whether primary, secondary, or tertiary – and align strategies accordingly.
This affects a range of businesses across the value chain, whether they produce packaging, import packaging or distribute packaging. Retailers and hospitality also have to comply or face a penalty.
Daudt emphasized that the regulation’s core objective is not just about recyclability, but reducing packaging waste overall. Plastic packaging receives particular focus due to its environmental impact and recycling challenges. Companies that produce, import, distribute, or retail packaging in the EU will bear responsibility, including data collection and reporting.
Tailored interpretation is key: materials, labelling, sector-specific exemptions, and operational context must be evaluated individually. For instance, reusable options are mandatory in hospitality, while space efficiency in transport packaging is enforced. Failure to act by January 1, 2030 will result in market access being denied.
She highlighted the importance of really knowing your own packaging, as there are no one size fits all rules.
“Think about whether you have primary, secondary or tertiary packaging, understand the materials in your packaging, whether they can be reduced, recycled or reused, and what sort of labelling is required.”
Step 2: Assessing your packaging portfolio
Most businesses are still in early stages of data collection.
“Many don’t even know what types of plastic they use, let alone whether it contains recycled content,” Daudt noted.
Accurate portfolio data is foundational, and presents a checklist to support proper packaging assessment:
• Start collecting packaging data
• Is it B2B or B2C packaging?
• Work closely with your supply chain
• Focus on products with higher volume
• Prioritize what the consumer needs
• Evaluate packaging material types (mono material vs problematic material)
• Choose the items that are easy to replace
• Review your packaging range against the RecyClass or CEFLEX standards
• Evaluate the potential to change design and reduce packaging material
• Create a hierarchy approach (volume/material type/complexity/design)
She advised prioritizing high-volume products and packaging types with the greatest business impact.
“Start with ‘low-hanging fruit’ – non-food applications or mono-material items that are simpler to change. Then gradually tackle more complex designs and sensitive applications.”
Regulatory standards such as RecyClass and CEFLEX should be used to evaluate packaging against recyclability classes. For example, by 2030, only RecyClass Class A and B will be acceptable, and Class C will be phased out, she pointed out.
Step 3: Identifying compliance gaps and opportunities
Daudt introduced a hierarchy approach to help companies prioritize action using weighted criteria – such as volume, recyclability, and design complexity – assigning scores from one to five and summing them to highlight
where to start. With this system, a crisp packet, for example, would receive a score of 23, a PET bottle a score of 11, and a milk carton a score of 15.
“You can then allocate teams’ time and resources to higher scoring items to work on high scoring items, which have a higher priority.”
Once assessments are complete, gaps and opportunities become clear. These insights form the foundation of a tailored PPWR action plan.
As Anna Perlina explained, “This is not just a regulatory checklist – it’s about aligning packaging vision with business success.”
Step 4: Building an action plan based on your priorities
Building a plan is based on defining your packaging vision, identifying main risks and opportunities, setting priorities and building a tailored retroactive PPWR timeline. Here it is important to find the common denominator between packaging functionality requirements, PPWR impact, business objectives and restraints and consumer insights and buy ins.
Perlina recommends mapping packaging functionality, sustainability, consumer acceptance, and regulatory targets to create a comprehensive vision and to use a SWOT analysis to audit the current situation. For example, this could look like the following:
• Strengths: Existing compliant packaging or flexible co-packing capabilities.
• Weaknesses: Use of composite materials or lack of traceability.
• Opportunities: Technological advancements or availability of scalable, compliant solutions.
• Threats: Uncertainty in future recyclability thresholds or fragmented infrastructure across EU states.
Mapping impact versus difficulty of addressing each factor allows teams to focus on high-impact, feasible actions first.
Perlina advised mapping actions and goals on a visual PPWR timeline to spot resource gaps, red flags, and long-lead-time changes. This visibility supports internal alignment and external reporting.
Renata Daudt:
“What is the penalty for not doing anything? You cannot have your packaging on the EU market.”
Step 6: Implementing changes, sourcing certifying
The final step involves implementation and certification. Perlina highlighted several practical tips for this stage:
1. Reduce Complexity First: Streamlining packaging formats and supplier bases can generate savings, freeing up budget to fund regulatory compliance efforts.
2. Create Technical Briefs: Clearly define packaging requirements up front to ensure supplier proposals are comparable and actionable.
With a vision in place and priorities identified, companies can start shaping a realistic path forward.
Step 5: Finding solutions
“Don’t be tempted by shortcuts,” Perlina warned. “Start broad and map all viable packaging options – regardless of format or material. Then assess functionality, regulatory fit, lifecycle impact, and feasibility.”
As a pathway towards solutions, Perlina talked us through a decisionmaking flow diagram.
The first step is to identify existing packaging options for your product category, followed by evaluating packaging functional requirements.
“It’s recommended to assess the entire range of packaging options you have, irrespective of packaging material, irrespective of packaging format, irrespective of single use, reuse, et cetera. So just map what’s available out there. The next step is to assess the functional requirements.”
After that it’s time to assess compliance with EU PPWR requirements and consider life cycle impacts. Next steps are to implement feasibility and viability and make the final choice.
“Here, again it is good practice to map packaging options and give different options scores across functionality, PPWR assessment, LCA impact and feasibility,” she points out.
“People sometimes ask if it makes sense to start with feasibility. This can make sense from a business perspective, but what we want is the proof of assessment that we’ve done so that we didn’t exclude any option and to be open to the best option. This mapping will be a tool to communicate with your stakeholders and with your consumers to explain how you make those choices.”
3. Leverage Off-the-Shelf Solutions: Existing, commercially available solutions that meet functional and regulatory needs should be prioritized to meet PPWR deadlines efficiently.
4. Consider Outsourcing: Third-party packers may help reduce capital investments and accommodate evolving regulations and market preferences.
5. Secure Post-Consumer Recycled (PCR) Content: With EU-wide PCR content requirements looming, particularly for plastic, companies must start early. The supply of food-grade PCR plastic is limited, so early sourcing and testing are crucial.
6. Get Third-Party Verification: Though self-assessments are accepted, third-party certification provides credibility, supports communication, and can reduce EPR fees.
Implementing packaging changes can take years. Daudt outlined a general timeline: Allow one month to interpret the regulation, one to three months for packaging assessment, one to three months to define gaps and opportunities, three to six months to develop a tailored action plan, three to six months to find and validate solutions, and up to two years for implementation. Cumulatively, full compliance can take up to four years. “2030 might seem far, but the clock is ticking. Act now,” Daudt stressed in conclusion.
Anna Perlina and Renata Daudt are content partners of Packaging Europe’s Sustainable Packaging Summit, which this year will take place in Utrecht in the Netherlands from November 10th to 12th. Join them alongside other leaders from across the value chain to share solutions, insights, and innovations as the industry moves towards a more sustainable future.
Anna Perlina:
“Don’t be tempted by shortcuts. Start broad and map all viable packaging options- regardless of format or material. Then assess functionality, regulatory fit, lifecycle impact, and feasibility.”
CUTTING COSTS AND CARBON FOOTPRINT: THE SUSTAINABILITY CASE FOR GENERATING NITROGEN IN-HOUSE
In the packaging and processing industry, decision-makers face a dual challenge: reducing operational costs while meeting ambitious sustainability goals. One often-overlooked opportunity to address both is in-house nitrogen generation. By producing nitrogen on-site instead of relying on bulk liquid deliveries or cylinders, companies can significantly cut costs and shrink their carbon footprint. This article explores data-driven insights into how on-site nitrogen generation benefits packaging operations and why Oxywise’s solutions are leading the charge.
The hidden costs of bulk nitrogen supply
Many packaging facilities use nitrogen for purposes like modified atmosphere packaging (MAP), inerting, or preserving product freshness. Traditionally, this nitrogen is delivered as bulk liquid or in cylinders. However, delivered nitrogen comes with a laundry list of hidden costs. Facilities pay not only for the gas itself, but also for transport, cylinder rental, and handling. Worse, a portion of delivered nitrogen often goes to waste – about 10% of the gas in a rented cylinder is typically returned unused, even though you’ve paid for 100%. Likewise, liquid nitrogen in on-site tanks continually evaporates (around 5% loss per day) if not used, leading to significant product loss and inefficiency
In-house nitrogen generation eliminates these inefficiencies. By producing nitrogen on demand, companies can avoid delivery fees and rental costs, and only generate the amount of nitrogen they actually need at the required purity. Multiple sources report substantial savings: on-site nitrogen can be 25–40% less expensive than bulk liquid supply once delivery and diesel fuel costs are factored out.
In fact, industry analyses show that switching to an on-site generator often reduces nitrogen costs by 40% to 80%, with a return on investment achieved in as little as 6 to 18 months. Some companies have seen even greater savings – one packaging manufacturer saved over $500,000 in just 18 months by moving away from bulk liquid nitrogen, fully paying back their generator investment in just over two years. Overall, in-house generation can slash nitrogen supply expenses by half or more, especially when replacing high-purity liquid nitrogen that your process might not even require.
Beyond direct cost savings, on-site generation also reduces less obvious costs like production downtime and administrative overhead. Relying on bulk deliveries means you’re vulnerable to late deliveries or supply shortages that could halt packaging lines. With an in-house system, nitrogen is continuously available – no more unplanned downtime due to empty tanks or delayed truck deliveries
Moreover, staff no longer need to spend time managing cylinder changeouts or hazard paperwork, and safety risks diminish when high-pressure cylinder handling is eliminated. In short, generating nitrogen in-house gives packaging operations greater control, reliability, and predictability in their supply – all while freeing up budget that was once eaten by gas suppliers’ margins and fees
Carbon footprint reduction:
Cutting emissions with on-site generation
Eliminating bulk nitrogen deliveries isn’t just good for the bottom line – it’s a powerful move for sustainability. Bulk liquid nitrogen has a surprisingly heavy carbon footprint. Consider the journey of delivered nitrogen: first, air is liquefied at an energy-intensive cryogenic plant (a process requiring large amounts of electricity and emitting significant CO2 then the liquid nitrogen is transported by diesel trucks to your facility, and finally it must be stored (with inevitable evaporation losses) and converted back to gas for use.
Every step of that supply chain – liquefaction, trucking, transfer – contributes greenhouse gas emissions. Studies note that “industrial cryogenic plants consume enormous energy and generate high volumes of CO2”, and each delivery can add tens or hundreds of road-miles worth of emissions. In fact, on-site nitrogen generation can be a major step toward sustainability goals: by eliminating an external supply chain, companies both reduce their carbon emissions and cut operating costs as a bonus
When you generate nitrogen in-house (typically via a Pressure Swing Adsorption (PSA) generator or membrane separation unit), you avoid the bulk of these emissions. There’s no need to liquefy the nitrogen or truck it across the country – the gas is produced at the point of use. This translates into dramatically lower energy usage and CO2 output per unit of nitrogen. For example, PSA systems generally use much less electricity than cryogenic production; one analysis found PSA generation uses roughly 28% less energy than producing liquid nitrogen at an air-separation plant for the same amount of gas.
Likewise, a leading manufacturer reports that on-site systems can save upwards of 50–70% of the energy (and corresponding CO2 emissions) for typical purity levels (95–99.9% N2) compared to delivered liquid nitrogen. Even at very high purities (99.9%+), on-site production is far more efficient – for many packaging uses, the cryogenic liquid route wastes energy that isn’t needed, since packaging often doesn’t require ultra-high 99.999% purity. By right-sizing purity to the application, on-site generators avoid the “energy penalty” of over-purification, further cutting electricity use and emissions.
Perhaps the most direct environmental benefit is the elimination of trucking emissions. Every nitrogen tanker delivery you no longer need means less diesel fuel burned. Simply by avoiding the liquefaction and transport stage,
“Say goodbye to the challenges of old nitrogen supply methods and welcome a streamlined, costsaving solution.”
on-site nitrogen generation not only reduces costs but also “reduces your carbon footprint” by cutting out delivery-related energy use.
For example, one facility found that its regular bulk nitrogen deliveries were adding nearly 7 metric tons of CO2 emissions per year – a footprint entirely erased by switching to an on-site generator. On a larger scale, the impact is even more impressive: industry data suggests that if a significant portion of users moved to on-site generation, millions of tons of CO2 could be avoided annually. These savings contribute directly to companies’ Scope 1 and 3 emissions reductions, helping packaging producers make tangible progress toward climate targets.
Aligning with packaging industry sustainability goals
Sustainability isn’t just a buzzword in packaging – it’s becoming a core business objective. From consumer goods brands pledging to hit net-zero emissions, to regulatory pressures for more efficient manufacturing, packaging companies are under pressure to decarbonize their operations.
In-house nitrogen generation offers a relatively straightforward win on this front. It directly addresses scope 2 emissions (by enabling the use of cleaner electricity for nitrogen production) and scope 3 emissions (by removing the need for supplier deliveries). Companies across industries are setting ambitious targets to cut their carbon footprints by improving energy efficiency and adopting cleaner technologies – and on-site gas generation is exactly the kind of innovation that helps achieve those targets in production environments.
Moreover, energy efficiency and cost efficiency often go hand in hand. Sustainable packaging operations aren’t only about recyclable materials; they also involve streamlining processes to use less energy and create less waste.
Nitrogen generators contribute to this by optimizing energy use (producing only the needed gas at the needed purity) and eliminating wasteful practices like over-purchasing gas or venting evaporative losses. This can also aid in regulatory compliance and reporting. For example, companies in the EU and UK now have to monitor and report their greenhouse gas emissions and energy consumption.
By showing a reduction in fuel usage for logistics and improved on-site energy efficiency, a packaging firm can demonstrate compliance with energy efficiency schemes and even potentially earn sustainability certifications or incentives. Additionally, reducing truck traffic for gas deliveries improves site safety and lowers risk, aligning with the industry’s broader commitment to safe and sustainable operations.
Importantly, packaging quality and productivity are never compromised – they’re improved. On-site nitrogen ensures an uninterrupted supply for critical packaging processes like MAP for food products or inerting for chemicals. There’s no risk of a supply contract cap or delivery delay causing product spoilage or compliance issues.
Instead, packagers gain self-sufficiency. This reliability means they can confidently pursue leaner supply chains and just-in-time operations,
Oxywise: Leading the way in in-house nitrogen solutions
As the case for in-house nitrogen generation grows, Oxywise has emerged as a go-to provider for packaging companies seeking to implement this solution. Oxywise’s energy-efficient, PSA-based nitrogen generation systems are engineered to deliver nitrogen reliably, safely, and at the optimal purity for your application.
In practice, this means a consistent, on-demand nitrogen supply tailored to your facility’s needs – whether you’re running high-speed beverage canning, food packaging lines, or specialty packaging for pharmaceuticals. Oxywise systems are built to be dependable, costeffective, and flexible, providing a steady flow of nitrogen at the required pressure and purity
By producing nitrogen right where you need it, Oxywise helps your operations run smoothly and efficiently. Users can essentially “say goodbye to the challenges of old nitrogen supply methods and welcome a streamlined, costsaving solution.”
What sets Oxywise apart is not just the equipment, but the partnership it offers. Packaging companies often have unique requirements – from space constraints to variable flow demands – and Oxywise specializes in tailored solutions to meet those challenges. The company has a track record in the industry (including the food and beverage packaging sector) and is known for its commitment to innovation and customer success
Oxywise’s nitrogen generators come with features that maximize efficiency (for instance, advanced flow control and purity monitoring) and minimize energy use, directly translating to lower operating costs for clients. By eliminating the need for regular nitrogen deliveries, reducing associated transport emissions, and cutting handling costs, Oxywise installations create immediate value on both cost and sustainability fronts.
Equally, they improve safety by removing high-pressure cylinders from the workplace and ensure production continuity by avoiding supplier dependency.
Conclusion: A win-win for cost and sustainability
In an environment where every penny counts and every kilogram of CO2 is scrutinized, in-house nitrogen generation stands out as a win-win strategy. Packaging and processing companies no longer need to choose between saving money and doing the right thing for the planet.
By generating nitrogen on-site, they can dramatically lower operating costs while simultaneously reducing emissions – a true alignment of economic and environmental objectives. The data is compelling: companies have saved tens to hundreds of thousands of dollars per year by switching to on-site nitrogen, all while cutting out the fuel consumption and pollution of weekly truck deliveries. These benefits directly support the packaging industry’s drive toward efficiency, sustainability, and resilience in the supply chain.
As you look to the future of your packaging operations, consider the impact that a more sustainable nitrogen supply could have on your business. Cutting costs and carbon footprint need not be mutually exclusive goals – with modern nitrogen generators, they reinforce each other. Whether you’re pursuing corporate carbon targets or simply trying to remove unnecessary costs, the sustainability case for in-house nitrogen is clear. Forward-thinking packaging companies are already reaping the rewards in cost savings, emissions reductions, and improved operational control.
Now is the time to evaluate your nitrogen supply strategy. By partnering with experts like Oxywise, you can assess the feasibility and benefits of onsite generation tailored to your needs. Oxywise’s proven solutions and industry expertise make the transition seamless, turning your nitrogen supply into a competitive advantage. Cutting costs while cutting carbon is a powerful step towards a more sustainable and profitable future for any packaging operation. The question isn’t whether you can afford to generate your own nitrogen – it’s whether you can afford not to. Reach out to Oxywise to explore how in-house nitrogen generation can elevate your packaging sustainability and bottom line.
Visit www.oxywise.com for more information
TURNING AMBITION INTO ACTION A LOOK AHEAD AT THE SUSTAINABLE PACKAGING SUMMIT
The Sustainable Packaging Summit brings together the entire packaging value chain – from start-ups and material innovators to global brands, investors, policymakers, researchers, and academic leaders.
We asked two key speakers about the sustainability challenges the packaging industry faces, what inspired them to be a part of the event, and what the focus of their session will be.
Willemijn Peeters, CEO and founder of Searious Business, will be a keynote speaker, and Dagny Tucker, co-founder of Perpetual Reuse, will be part of the ‘Reuse: From Success Stories to Scale’ panel.
Packaging Europe: Please introduce yourself and the work you do.
Willemijn Peeters: I’m the founder of Searious Business, a company dedicated to preventing plastic pollution at its source. Since 2016, my team and I have worked with global brands like Unilever and Danone to redesign packaging systems and accelerate the transition to a circular economy. Our mission is clear: to keep plastics out of the ocean by driving upstream innovation and systemic change.
Dagny Tucker: I’ve come to the subject of reuse from a bit of an unusual background. My PhD is in international peace and conflict, where I spent a lot of time looking at the drivers of violent conflict, a lot of which are resource-driven. I was interested in the social and environmental impacts of hyper-consumerism.
I also have a master’s degree in design and felt that there was a huge gap in understanding the impact an individual packaging choice could have.
Back in 2012, reuse wasn’t really a concept in packaging. We designed and built an open network reusable service system in New York City from scratch. It was a big push to get businesses to participate. Technology was emerging, but nascent.
After about three weeks of using the service, 85% of respondents said that they began to rethink each of their daily single-use disposable habits. Achieving meaningful behaviour change was a Eureka moment for me. We launched in California as well as Colorado and ran the system for many years. We decided to set up Perpetual Reuse as a non-profit to address the gap in technical expertise that was being shared and address some of the biggest problems in reuse.
Summits like this aren’t just another date on the event calendar –they can act as a catalyst. What makes this one so powerful is that it brings together the right people from across the entire value chain.
issue, and an infrastructure and systems problem.
We have seen some investment, but part of the investment challenge is tied up with the scale challenge. It’s a chicken-and-egg problem. Companies are happy to invest when you can show them scale, but without investment, it’s very hard to do so. Furthermore, in many instances, reuse has been popular with a segment of the population that cares about the environment and can afford it, but it’s not accessible to everybody.
We need to have full-scale demonstrations of reuse to show how it can work in real life. We are laser-focused on setting up such full-scale reuse systems and have done so in four cities in the US: Ann Arbor, Galveston, Hilo and Savannah.
Price parity is another challenge. There is a gap between the cost of a single use and a reusable item, which needs collecting, washing and reinstating, although there are some successful reusable glass bottle systems in place, where multinationals have stringent reverse logistics agreements.
While policy is an important driver, we intentionally chose policy-free interventions. The systems we’re setting up in the US are permanent, longterm systems that start at scale on day one.
PE: Willemijn, what are some of the biggest challenges the packaging industry faces around circular (or not so circular) plastics and reducing plastic waste, and how can these be addressed?
Improving recycling alone won’t solve the problem. There’s too much to process, and the system is already overwhelmed. That’s why we have to put reuse front and centre.
Reuse has massive untapped potential. It can dramatically reduce overall packaging, cut costs, and completely reimagine how we deliver products. While there are promising pilot projects, reuse still makes up only a small fraction of most packaging portfolios. To truly scale reuse, we need shared logistics systems, enabling policy frameworks, and real incentives for both companies and consumers. Behaviour change on a mass scale is tough, but it’s doable. With smart engagement and consistent effort, we can shift habits. Right now, the infrastructure and coordination simply aren’t in place. This is where businesses can lead by collaborating across value chains, investing in new delivery models, and supporting policies that level the playing field.
Of course, recycling still has a role, but only as part of a broader circular strategy. The current system is patchy and inconsistent, especially when it comes to difficult materials like flexible or multilayer plastics. We need major investment in harmonized design standards, collection, and sorting systems. Even when materials are recycled, quality is a major challenge. Contamination and inconsistent feedstock make it incredibly hard to achieve reliable, food-grade recycled content.
The root of the problem is that packaging is still primarily designed for shelf appeal or basic functionality, not for circularity. That thinking
more piece that is critical: True Pricing. Virgin fossil-based plastic remains far too cheap, thanks to subsidies and the fact that its environmental costs – pollution, emissions, resource depletion – are completely externalized. If we priced plastic according to its real impact, circular alternatives would suddenly become much more attractive and viable.
At Searious Business, we’re tackling these challenges head-on. We work with brands to redesign packaging systems, advocate for better policy, and build collaborations that can truly move the needle. Circularity isn’t just a technical fix, it’s a mindset shift. With the right ambition, alignment, and courage, we believe we can redesign the system for good.
PE: Could you give us a sneak preview of some of the themes that will be covered in your keynote/panel at the Sustainable Packaging Summit?
WP: My keynote is titled “Beyond Box Ticking: Ambitious Design That Makes Regulations Irrelevant”. It’s about pushing the conversation much further. Much of the packaging industry is focused on specific materials – paper, flexibles, metal – and trying to keep up with compliance. While that’s understandable, it’s not in their long-term interest. What we really need is a bold rethink of packaging itself: its role, its form, and how it fits into business models of the future. Instead of just making single-use packaging slightly better, why not design durable, modular, multi-use systems that make regulation redundant? This isn’t wishful thinking either - I’ll be sharing real-world projects that prove it’s possible. These innovations cut waste, emissions, and costs. They show that when you lead with smart, ambitious design, you don’t have to scramble to meet regulations – they
DT: It will be a fun duo on stage with Eunomia’s Tom Domen. We will look at emerging trends globally and what is happening in the industry. We are the executing partner for reuse and refill for the Global Environment Facility project, which includes several multilateral funds working together to address the planet’s most pressing challenges in an integrated way. Furthermore, we will look at significant legislation in California: SB 54, the California Plastic Pollution Prevention and Packaging Producer Responsibility Act, which has very distinct reuse targets attached to it, similar to the PPWR in Europe. We have several projects in California looking at what is required to meet these obligations, and hopefully, we will have some insights from that to share, as well as where we are with our city pilots. We will also discuss how to bring municipalities who do not yet have structures in place up to speed.
PE: What inspired you both to take part in this year’s Sustainable Packaging Summit as a speaker?
WP: One of the reasons I was keen to speak at this year’s Sustainable Packaging Summit is the way it brings together such a broad mix of voices from across the industry – and that’s very much down to Tim Sykes’ leadership. He has a great helicopter view of the sector and a real knack for connecting the dots between different parts of the value chain. What I really appreciate is how he creates space for open, honest conversations – bringing people together without pushing a particular agenda. He’s genuinely curious, committed to sharing insight, and manages to stay remarkably impartial... even though I’m sure he has opinions of his own! That kind of
openness encourages real collaboration, and that’s what the summit is all about. It’s become a hub for meaningful dialogue and practical progress - the kind of space we need if we want to drive real change. I’m looking forward to contributing to that conversation and offering a fresh perspective.
DT: We get a lot of speaking requests and try to be selective. The Sustain able Packaging Summit has been continuing to grow as a vibrant event, and especially with the PPWR, reuse has taken centre stage, which gives us the chance to get out the most relevant and timely insights and knowl edge, and we would like people to run with it.
PE: What role do you think summits like this can play to foster col laboration and boost solutions across the value chain?
DT: Events like this offer an important platform for knowledge sharing, where stakeholders can come together in a non-competitive environ ment, learn and meet the experts to be able to develop the relationships that enable them to make the changes they need to be successful. This is important, particularly as we’re looking to transform entire supply chains.
WP: Summits like this aren’t just another date on the event calendar – they can act as a catalyst. What makes this one so powerful is that it brings together the right people from across the entire value chain. And not just to talk, but to listen, to challenge each other, and to start building the partnerships we need. When you get brand owners, designers, recyclers, policymakers, and innovators all in one room, you create a rare kind of momentum. You start seeing real solutions emerge, and more importantly, you see where they can connect and scale. What I love about this summit is that it doesn’t just spotlight ambition, it pushes for true impact and for systemic change through radical collaboration. This gathering helps turn ambition into action.
Don’t miss out on this premier event!
Scan the QR code for tickets
When: November 12th to November 14th, 2025
Where: Jaarbeurs Event & Exhibition Centre, Utrecht, Netherlands
What to expect:
Timely insights on regulatory change and industry trends
Breakthrough innovations in sustainable materials, technologies, and systems
Dedicated networking breaks, interactive breakout sessions, and an unmissable block party in the exhibition hall
Opportunities to form new partnerships, explore funding and investment, and connect with decision-makers and disruptors from across the globe
SPOTLIGHT ON THE EVOLVING BEVERAGE AND LIQUID FOOD MARKETS
Demographic shifts, health and nutrition trends, and ever-shorter product life cycles are shaping developments in the beverage and liquid food industries. These industries also face stringent requirements concerning food safety and quality, alongside demands for efficient and sustainable production and packaging solutions – increasingly driven by data and digital tools. We take a look at market trends, challenges and solutions ahead of drinktec 2025.
Many companies in the beverage and liquid food sector have set their own sustainability targets, with a focus on areas such as intelligent circular systems and sustainable resource management in both production and packaging.
Showcasing a lot of these developments, drinktec, the trade show with a focus on the liquid food and beverage industry, will take place in Munich in Germany from September 15th to September 19th, 2025, spotlighting the latest trends and developments that address major industry challenges, covering the entire value chain.
Sustainability challenges
The responsible use of resources is not only an issue in the beverage and liquid food industry, but it affects all economic processes. Circularity and resource management are global issues.
The focus of the beverage and liquid food industry as showcased also at drinktec is on intelligent circular systems and sustainable resource management in both in production and packaging process.
The focus of digitalization is on creating added value through data: By evaluating machine and process data, the use of resources can be optimized, production downtimes can be reduced and plant utilization can be made more flexible.
Plastic packaging is subject to intense political and social debates, which has put pressure on consumer goods manufacturers to act towards sustainability and packaging reduction.
Material-optimized, lightweight and easily recyclable packaging are key issues. New fibre-based packaging materials and recycling methods for multilayer packaging also contribute to the goal of a sustainable circular economy.
The EU’s Packaging and Packaging Waste Regulation (PPWR), which came into force in February 2025 and will apply in all EU countries after an 18-month transition period, stipulates among other things, a higher proportion of recyclate for plastic packaging in order to reduce the use of primary raw materials. Circular systems for packaging are also to be strengthened. The PPWR could therefore give a further boost to resource conservation and sustainable packaging – even beyond the EU.
Under the umbrella of ‘Circularity & Resource Management’, at drinktec, topics such as water reuse and waste water treatment will be addressed. Presentations will explore how global requirements for water conservation can be implemented from various perspectives. Additional focal points include energy recovery, the use of by-products from production processes,
and more efficient packaging material usage. The implementation of the EU’s Packaging and Packaging Waste Regulation (PPWR) will also be reflected in the lecture programme.
Machine learning and AI
The second topic relevant to the packaging industry at drinktec, ‘Data2Value’, focuses on process transparency and the integration of machine learning and AI-based applications. Topics include flavour prediction models and predictive maintenance. These approaches also apply to cleaning process design: AI combined with machine learning enables the detection of contamination levels in containers and triggers self-adjusting cleaning cycles accordingly.
Digitalization plays a pivotal role in unlocking savings, optimization, and improvements along the value chain. In the service sector, apps and assistance systems have become essential components of digital value-added services. Simulating production processes using AI and digital twins is becoming increasingly relevant – particularly in making complex investment decisions.
The focus of digitalization is on creating added value through data: By evaluating machine and process data, the use of resources can be optimized, production downtimes can be reduced and plant utilization can be made
more flexible. Data and its use generate added value in terms of increased efficiency, product safety, improved availability, performance and safety of machines and systems as well as transparency throughout the entire manufacturing and packaging process.
Evolving markets
At a press conference ahead of drinktec 2025, VDMA, the German association of around 3,600 German and European mechanical and plant engineering companies, and conceptual partner of drinktec, reported a decline in production within the food processing and packaging machinery sector of just under 2%, falling to €16.1 billion. At the same time, exports increased significantly by 6% to €10.6 billion.
“In 2024, investment activity in Germany was significantly weaker than expected, meaning that even the sharp increase in foreign shipments could not offset the decline in domestic sales,” explained Richard Clemens, Managing Director of the VDMA Food Processing and Packaging Machinery Association.
Only the packaging machinery segment recorded an overall increase in production, rising by 2% to 8.3 billion euros, driven by growth in the subsegment of beverage packaging machinery.
With an average export share of 84% the food processing and packaging machinery sector is among the most export-intensive in German mechanical engineering. In the first quarter of 2025, exports increased by 3.4% compared to the already high level of the previous year. More than half of these exports were shipped to non-European countries.
The United States has reportedly been by far the most important market for German manufacturers of food processing and packaging machinery for many years. In 2024, Germany exported machinery worth €1.8 billion to the U.S., marking a 7% year-on-year increase.
However, according to a recent VDMA survey, a clear majority of mechanical engineering companies report growing uncertainty regarding the U.S. market: 87% have business ties with the U.S., and of these, twothirds operate their own local sales offices.
“We hope that negotiations with the EU Commission will bear fruit. High tariffs – or worse, a trade war with the European Union – would ultimately mean losses for everyone,” said Clemens.
Despite the tariff concerns, he expects many visitors from the U.S. market to attend drinktec 2025. “With over 1.5 million employees, the U.S. food industry is the largest manufacturing sector in the country. Automation and capacity
expansion are key drivers of investment. American companies cannot meet their technological needs domestically,” said Clemems, referencing EU imports of food processing and packaging machinery, which amounted to €5 billion in 2024.
“We see our industry as a crucial part of the solution. After all, who better than machinery manufacturers to help shape production processes that are not only efficient and economical, but also sustainable?”
Only the packaging machinery segment recorded an overall increase in production, rising by 2% to €8.3 billion, driven by growth in the sub-segment of beverage packaging machinery.
PACKSYS PRESENTS NOSHO –THE CAP-FREE, PLASTIC-SAVING SHOULDERLESS TUBE
In this edition of our ‘In Conversation With…’ series, Julius Läubli, head of Research & Development at Packsys, walks us through the company’s noSho shoulderless tube innovation – outlining its potential to reduce plastic consumption and emissions, streamline the recycling process, and integrate into existing machinery.
Could you give us a rundown of noSho for anyone who may be hearing about it for the first time?
noSho is an innovative tube solution developed for the high-end cosmetic market, designed to minimize material use while simplifying the packaging process.
Based on proven compression moulding technology, it enables the entire tube head, including the re-closable lid, to be produced in a single production step.
Additional components such as pre-moulded tube shoulders and conventional caps are completely eliminated.
This reduces plastic consumption by up to 80% compared to standard tubes and not only makes noSho more sustainable, but also streamlines the entire production and packaging chain.
Where did the inspiration for this design come from? Is it intended to meet any specific market needs or respond to certain legislation?
The noSho concept emerged from two key industry drivers: growing sustainability demands and the need for operational efficiency. With increasing consumer awareness and tightening environmental regulations, especially in the cosmetics and personal care sector, packaging that uses fewer materials and simplifies the recycling process is in high demand.
noSho responds directly to these needs – offering a forward-thinking solution that is both resource-conscious and recycling-friendly.
Do you have any case studies or data to quantify the amount of plastic this solution saves?
Yes, internal production benchmarks have shown that noSho requires up to 80% less plastic compared to conventional tube-and-cap designs. By eliminating the cap and using a simplified tube head, the reduction in raw material is significant.
For example, with an annual production of 20 million tubes, customers can achieve savings of up to 178 tons of plastic, 2.7 tons of masterbatch, and 1,100 tons of CO2 – resulting in cost savings of
approximately USD 450,000 per year. Further data from ongoing field use and pilot applications is being collected to quantify long-term sustainability benefits.
Can you elaborate on how this bottle design improves production efficiency?
By eliminating the need for components like pre-moulded tube shoulders and traditional caps, noSho removes the entire supply chain for parts, application processes, size components, and feeding systems.
This not only saves production floor space but also reduces changeover time and streamlines the workflow. Overall, manufacturers benefit from shorter production cycles and lower total operating costs.
How can customers integrate noSho into their packaging lines? Does it require retrofitting or further investments?
noSho is designed to be as easy to integrate as possible. It is compatible with existing PackSys Global Prestige Header/Capper machines, requiring only minimal upgrades. No major retrofitting is necessary.
Upgraded machines still allow quick changeover between regular tube production and noSho design. This ensures a low entry barrier and a fast transition from conventional tube formats to the noSho system.
What markets and/or applications would you recommend noSho for?
noSho is ideal for high-end cosmetic and personal care products, especially those where sustainability and aesthetics go hand in hand. It’s particularly suited for brands that wish to differentiate with minimalist, eco-conscious packaging without compromising functionality.
Due to its simplified production and resource savings, it can also be a strategic choice for companies aiming to meet ESG (Environmental, Social, and Governance) targets or plastic reduction commitments.
To learn more about the noSho shoulderless tube, visit: www.packsysglobal.com/en/Technology-Innovation/noSho
Julius Läubli
AN INSIDER’S GUIDE TO SMURFIT WESTROCK’S FIRST YEAR AS A COMBINED COMPANY
One year into its combination, where does Smurfit Westrock stand? President and CEO of EMEA & APAC Saverio Mayer runs us through its implications for the customer experience, the company’s financial and reputational benefits, and the potential next steps in this edition of our ‘In Conversation With…’ series.
First of all, what effect has the combination had on strategic intent? Have you experienced any commercial or financial developments?
One of the biggest benefits of Smurfit Kappa and WestRock combining was the fusion of two such complementary product portfolios. We now have proven capability as a true one-stop-shop for customers; the breadth and quality of the Smurfit Westrock product offering is best placed to meet all packaging requirements.
Furthermore, we have the expertise to advise on primary and transport packaging to ensure they work together seamlessly to reduce wasted space and improve efficiency. Our long-term experience in machinery and automation means this can all be brought to life in-house.
Our expanded geographical footprint allows us to satisfy the needs of multinational customers who depend on a global approach, while our in-country knowledge and on-the-ground teams can successfully facilitate local needs, too.
Can you elaborate on the medium- and long-term value creation resulting from the combination?
The combination allows us to build a strategic plan that cements us as the leading provider of innovative and sustainable packaging solutions. In the medium to long term, we want to be seen as the packaging supplier that makes things easy through our expertise in innovation, manufacturing, packaging systems, and customer service.
We are building a performance-led culture, which is going to be the bedrock of our future success, and are all encouraged by the progress we have made so far. The synergy programme of $400 million that we shared at the outset is on track, and we have also identified opportunities to create additional value of over $400 million.
There were several sustainability wins during the year, including an ambitious electrification scheme at our Roermond paper mill in the Netherlands, a true frontrunner in the transition to low-carbon operations.
How have customers reacted to the combination so far? What would you say they have gained as a result of Smurfit Westrock’s combined efforts?
Overall, our customers have reacted positively as our increased global presence benefits them – but, crucially, our personal touch remains, and we have been told by several customers that this is both appreciated and valued.
In terms of their gains, they have an even greater pool of expertise at their disposal, and the possibility of greater efficiencies and more innovative solutions driven by the collaborative nature of Smurfit Westrock. We’ve recently got several supplier awards for both sustainability and innovation, and this customer recognition is nice to see.
As an insider, how would you describe the experience of becoming a truly integrated company?
The Smurfit Westrock integrated business model generates real value for our markets. We own our own supply chain from raw materials through to paper production, collection, and recycling. Our fully integrated system of containerboard mills and corrugated plants provides constant quality, consistent delivery, and greater supply chain efficiency.
The integration of the two companies is going very well as the values and culture are aligned. This solid foundation, along with the quality of the assets and the commitment and expertise of our 100,000 people worldwide, has allowed us to move at full speed.
On a wider scale, how has Smurfit Westrock adapted to legislative developments, the European trading environment, and other evolving macroeconomic conditions?
We are already working with companies to prepare them for the forthcoming Packaging and Packaging Waste Regulation (PPWR), legislation which seeks to reduce packaging waste. Our job is to support businesses as they
Saverio Mayer, President and CEO of EMEA & APAC
transition to more sustainable packaging, and we have a broad portfolio of paper-based, recyclable products that comply with the new rules and are available for both manual and automated processes.
When it comes to the volatile macroeconomic conditions that have characterized recent years, we have found that the most important thing is to be adaptable, agile, and ready to evolve. Having a broad geographic footprint and differentiated offering helps us to balance challenges and opportunities.
Where does the company plan to go next? Can you give us any insight into future developments we should keep an eye out for?
Looking back at this first year, we can be proud of what we’ve achieved in such a short space of time, both operationally and in how we’ve already built a brand that stands for quality and security. We are also always building the business case for sustainability.
We’ve also begun to deliver for our customers, our people, and externally for our shareholders. However, we also know that we are at the start of a long journey and it will require effort, innovation, and collaboration to get to where we truly want to be.
There are still regions in which our presence is not strong enough right now, but with the right strategic plan in place, it soon will be. We don’t just want to be the biggest; we want to be the best, both for our customers and our colleagues. When you look at what we have achieved in one year, I am excited about what we will accomplish in the year ahead.
CIRCULAR PACKAGING: A MATTER OF MATERIAL AND MACHINES
The circular economy is a sensible approach to protecting the environment and valuable resources, provided different stakeholders are pulling in the same direction. Packaging and packaging machinery manufacturers play a vital role in ensuring that recycling is more than just an empty promise. Michael Graf, who leads Schubert’s Packaging Competence Center, sheds light on key challenges.
The importance of recycling and recyclability has grown, moving from a purely technical topic to a strategic asset. How has it affected major industries like food, beverages and cosmetics?
With growing consumer interest, as well as demands from legislators, the pressure on companies in the food, bakery and other industries is increasing. This is because a sustainable mindset knows no national borders. In Europe and the United States, consumers value ecologically manufactured products when shopping. Different studies show that consumers are not only willing to choose sustainable options over a similarly priced product. Respondents in the US and Finland, for instance, also said they would be willing to spend more – sometimes significantly – for products with sustainable packaging.
Where does this leave the packaging and the FMCG industries?
Recyclability is becoming a strategic and an image issue. A company may lose market share and reputation if it fails to meet the needs described. Sustainable, and wherever possible, recyclable packaging solutions are therefore becoming a long-term goal, as well as a major challenge – for the packaging and FMCG industries and their respective customers. In Germany alone, several million tons of packaging waste are generated every year. New approaches to packaging are needed to reduce this amount over the long term and to significantly increase recycling rates.
How can FMCG manufacturers use more sustainable materials in the packaging process while remaining profitable?
The first thing they need to do is address the entire packaging ecosystem, from the materials used to the consumers and the recycling process right back to the machines. Every material choice and design decision now car-
Michael Graf
ries unprecedented weight in determining whether we achieve true circular sustainability or continue feeding a linear waste system.
This also means they can tackle the issue from various angles to make their production more sustainable. For example, they can use packaging materials that are environmentally friendly because they are easy to recycle, and of course they can try to reduce the amount of material used in their packaging.
Let’s focus on the material for a moment. What options do food manufacturers and other companies have in this regard?
Because it is made from renewable raw materials, cardboard packaging comes across as sustainable at first glance. However, it is as a rule not entirely recyclable due to the glue used to seal the cardboard packaging. This glue is very energy-intensive to produce and requires the glue mass to be heated before it can be applied. Schubert developed an alternative approach called ‘Dotlock’.
The technology allows to join several layers of cardboard completely glue-free. To achieve this, the layers are pierced from one side with a needle, creating a collar on the other side. This is then pressed onto the cardboard, creating a stable force and form fit.
So, if the cardboard is fixed without glue, it can be easily recycled?
It depends on whether it contains additional materials. The more additional materials that are present, the more difficult it is to separate the components and recover the fibres.
For example, if cardboard has a PE or aluminium coating, separation becomes more complex and the results are lower. Simple, minimalist packaging solutions, on the other hand, offer recycling benefits and comply with the EU’s Packaging and Packaging Waste Regulation, which promotes the production and use of monomaterial packaging.
Manufacturers are therefore doing a lot to significantly reduce compos-
Mono-materials represent a change not only for the products themselves, but also for the machinery involved in their production. How can manufacturers ensure that these alternatives can be processed as efficiently as traditional materials?
Let‘s consider mono-films, which are made of a single type of plastic and are the easiest to recycle. However, they are primarily made of PP and therefore have a lower melting point than composite films.
As a result, a gentle sealing process is needed to use mono-films in flow-wrapping machines. And this is precisely what Schubert’s Flowpacker series delivers.
Among other things, it features Box Motion sealing technology. Thanks to the gentle ultrasonic sealing process, the machines are an excellent choice for polymers with a low melting point and paper-based films and do not require heat protection.
Does sustainability in the packaging industry thus call for added flexibility?
Definitely. Flexibility has always been a prerequisite, as it isn’t uncommon for food manufacturers to package different products to cover market segments as broadly as possible.
The range of novel packaging materials has increased, having an even broader impact on packaging processes that manufacturers must continuously adapt to. Flow-wrapping machines and cartoners from Schubert enable switching between different sealing technologies, product formats and packaging materials, paving the way for a truly circular packaging ecosystem.
Learn more: www.schubert.group/en/schubert-uk/
INSIDE MONDI FLEXSTUDIOS – AND ITS VISION FOR CIRCULAR PACKAGING
Mondi has inaugurated FlexStudios, a new 2300m2 research and customer experience centre in Steinfeld, Germany. This state-ofthe-art facility aims to foster the co-creation of flexible packaging solutions and promote a more sustainable future. Dominique Huret from Cape Decision attended the grand opening to provide an exclusive report for Packaging Europe.
With the opening of FlexStudios, Mondi is emphasizing its commitment to sustainable innovation. This state-of-the-art centre is a place where ideas take shape, giving customers the opportunity to work together to develop and refine fit-for-purpose packaging solutions. By focusing on collaboration and smart design, Mondi is paving the way for a more sustainable packaging industry.
Mondi’s FlexStudios spans three floors of interactive space. One floor is dedicated to FlexStudios Inspire, an area for collaboration and creativity to develop fit-for-purpose, sustainable packaging solutions that meet consumer expectations and goals.
Credits: www.diefirma.de - Isabel Schaefer
Walking down the creative floor of FlexStudios Inspire, most of Mondi’s recent award-winning packaging and numerous collaborations are showcased. “We prefer a reverse approach to presentations,” says Petra Nothdurfter, Head of Communication and Marketing for Flexible Packaging at Mondi. “Thanks to multiple interactive screens and product displays of Mondi’s sustainable packaging and paper solutions, we help our customers share and understand their needs and requirements. We listen to their challenges and together, we start to build innovative concepts.
“Among our recent paper projects, we have developed 100% paper Mailer packaging for Amazon, recyclable bread bags made of our FunctionalBarrier Paper and light-weight paper shopping bags containing recycled fibres. As far as flexible plastic packaging is concerned, one of our major plants is located right next door. Today, brand owners, particularly in the pet food sector, are increasingly turning to us for alternatives to multi-layer packaging and aluminium pouches. Much of our recent work in this area has focused on the creation of our re/cycle FlexiBag Reinforced – a mono-PE bag for dry pet food – as well our re/cycle Retort Standup Pouch – a mono-PP pouch suitable for sterilization. All the functionality of the packaging is retained, with only a slightly shorter shelf life, which is accepted by both consumers and brand owners. Sustainable solutions are becoming a must.”
Once the customer has an idea of their desired packaging, they are guided to the FlexStudios Innovate floor, where the feasibility checks begin.
“This is our pilot facility to test and develop new packaging solutions,” says Catia Costa, R&D Centre manager at Mondi Steinfeld FlexStudios. “We have a wide range of equipment: extrusion coating/lamination, print-
Credits: www.diefirma.de - Isabel Schaefer
ing and lamination equipment (solvent free, solvent based, water based), slitting as well as packaging and filling lines for different materials.
“This includes both horizontal and vertical filling, thermoforming and sealing. This allows customers to conduct trials without interrupting their own running production.
“The circular economy also needs to be understood as a business opportunity, a smarter, more sustainable way to drive growth. Building a sustainable circular economy means everyone needs to work together.”
“In addition, we apply our material neutral approach, providing expertise in both paper and polymer packaging. This is a valuable asset to demonstrate our products’ performance and we can accelerate the whole production process.
“For me personally, this is a one-of-a-kind project and a fascinating opportunity to connect R&D and customers.”
The third part is FlexStudios Advance, which contains the laboratory and testing facilities. Here, as explained by Head of Innovation, Mondi Flexible Packaging, Elisabeth Schwaiger, “customers can benefit from our state-ofthe-art expertise on the packaging produced. With advanced testing and materials characterization, we can accelerate the process.
“This R&D centre aims to demonstrate our hands-on approach to developing sustainable packaging. We look forward to our dedicated work with our customers here at FlexStudios. Combining their knowledge with ours will allow them to meet their sustainable packaging goals.
“This investment also contributes to our Mondi 2030 Action Plan for sustainable development, and more specifically to our objective of making 100% of our products reusable, recyclable or compostable by 2025. Mondi also has an R&D centre dedicated to testing recycling and food safety in Frantschach, Austria.”
This is indeed a strategically timely investment. With ambitious targets mandated by the Packaging and Packaging Waste Regulation (PPWR), the whole value chain faces an urgent need for collaborative product development and testing of innovation. Industry will be dealing with bottlenecks in relation to launching solutions that are recyclable and contain recycled content – so a facility such as FlexStudios, created to reduce time to market for sustainable packaging innovations – addresses a pressing demand.
Before cutting the ribbon at the grand opening ceremony, Thomas Ott, CEO Flexible Packaging at Mondi, put this investment in context.
“We all have to realize that times have changed,” he said. “Back in the 1960s and early 1970s, everything revolved around consumption; this is what kept the economy thriving – the golden age of consumerism.
“Products were designed to have a built-in expiry date. The reasoning was simple: if things lasted too long, people wouldn’t buy as much.
“Fast forward to today; we’re now dealing with the environmental and societal fallout from this approach. That’s why there’s a growing shift away from the old-school ‘take-make-use-dispose’ economy to something better: a circular
economy. Here the goal is to keep products and materials in use for as long as possible by reusing, recycling, and regenerating them.
“We need to start pushing the idea of treating waste as a valuable business model at every step of the value chain. That means thinking more about the whole system.
“At Mondi, we are working on creating solutions that are sustainable by design and keep materials in circulation. After all, it’s not about pitting plastic against paper packaging. It’s about whether packaging is sustainable or not.
“The circular economy also needs to be understood as a business opportunity, a smarter, more sustainable way to drive growth. Building a sustainable circular economy means everyone needs to work together.
“Manufacturers, suppliers, consumers, and policymakers all have to collaborate: it’s the new way of doing things. Only by teaming up can we come up with solutions that balance what’s good for the planet with what works for business.”
Credits: www.diefirma.de - Isabel Schaefer
The debate of which is the better packaging material – paper or plastics – often is led in a binary way. But there are a lot of facets to this discussion.
To get a snapshot of industry opinion on the paper vs plastics debate, we spoke to a range of experts from industry associations and NGOs to get their take strengths, weaknesses and challenges of both materials.
PAPER VS PLASTICS BRINGING NUANCE TO THE DEBATE
ATour Sustainable Packaging Summit 2024, during a panel discussion on paperization, we asked our audience whether they thought that the trend offered a net environmental gain, and the answer was somewhat ambiguous, with 43% answering yes, 24% no and 33% undecided. This result shows that as is often the case in sustainability debates, there is no easy or straightforward answer – which is also mirrored by the statements of our panel of experts.
The plastics perspective
Virginia Janssens, Managing Director of Plastics Europe, is keen to highlight that Plastics Europe recognizes the growing interest in comparing plastics and other alternative materials through the lens of environmental impact but that while it may be tempting to seek a clear winner, the reality is far more nuanced.
“Plastics possess unique characteristics such as lightweighting, durability and versatility that make them indispensable in many sectors, including packaging. For example, barrier properties of plastics can prevent the entry of moisture, oxygen, light and contaminants, extending product shelf life (especially for food and pharmaceuticals). Substituting plastics with other
materials may be viable in specific applications, but we see a clear need to always look jointly at the application and the potential alternatives as otherwise it might not create the desired environmental benefits but risks unintentionally increasing environmental damage.”
She cites a study from the American Chemical Society that states that replacing plastics with alternatives is worse for greenhouse gas emissions in “most cases”. Meanwhile, Plastics Europe’s ‘Reshaping Plastics’ report states that only 4% of plastic waste can be avoided through the substitution of plastics with alternative materials.
“Plastics Europe advocates for an application-based approach and an assessment methodology that considers the full life cycle of materials from product design to end-of-life management. This means that we evaluate on a case-by-case basis and ensure that the best material for each instance is used,” she says.
This kind of application-based approach should apply to products made from all materials, she points out.
“It can help eliminate the production of problematic products and promote the replacement of short-lived or single-use items with durable alternatives, provided they demonstrate a reduced environmental footprint.
Vanessa Janssens:
“Plastics Europe advocates for an application-based approach and an assessment methodology that considers the full life cycle of materials from product design to end-of-life management.”
Winfried Muehling:
“Choosing the right packaging has become more complex as both product protection and life cycle environmental impact must be considered.”
Such an approach also takes into account health, safety, and socio-economic factors. Our position is grounded in evidence-based assessments and lifecycle thinking.”
The case for fibre-based packaging
Winfried Muehling, Marketing and Communications Director at Pro Carton points towards the advantages of fibre-based packaging while acknowledging the role of plastics.
“Choosing the right packaging has become more complex as both product protection and life cycle environmental impact must be considered. While both fibre-based and plastic packaging have roles depending on the product requirement, consumer preferences clearly lean toward fibre-based solutions. According to a recent Pro Carton Europe-wide survey, nine out of ten consumers prefer fibre-based packaging due to its renewable origin and the trust they place in established collection and recycling systems.”
He highlights challenges around recyclability by pointing out that in today’s regulatory context, being merely “recyclable” is no longer sufficient.
“What matters – for consumers and legislators – is the proof to recycle at scale. Fibre-based packaging already achieves this, with a recycling rate of 83.1%, compared to only 40.1% for plastics, according to figures from Eurostat. This infrastructure advantage strengthens the case for fibre-based materials within a circular packaging system.”
“From 2018 to 2021, CO more efficient resource use and an ever-increasing share of renewable energy in production. As life cycle assessments become more granu lar, such progress further validates fibre-based packaging as a leading sustainable choice. A strong collection and recycling system, combined with renewable inputs, makes fibre-based packaging well-positioned as a leader for circular economy.”
The flexible packaging view
Dana Mosora, Consultant at CEFLEX, mirrors the experts from Mondi and points out that in the flexible packaging industry, it is important to look at each use case individually and make sure the flexible packaging material delivers on the specific performance requirements of the end application in scope.
“Therefore, to say that either plastic or paper is the winning choice across the board cannot be the right answer. What we know is that when flexible packaging is designed with the D4ACE guidelines in mind it can fit its purpose for each application and be recycled which makes it the right choice.”
A complex challenge
Alix Grabowski, Senior Director Plastic and Material Science, WWF-US, points out that the paper vs plastic question is too binary to deal with the complexity of the challenge.
He also pinpoints environmental performance improvement with fibrebased packaging.
“There’s a reason the results of every major study on plastic pollution point to a suite of solutions all contributing to broader systems change –
Dana Mosora:
“When flexible packaging is designed with the D4ACE guidelines in mind it can fit its purpose for each application and be recycled which makes it the right choice.”
Alix Grabowski:
“We must do more with less, build better, more circular material systems that deliver real benefits to both people and nature and respect planetary boundaries.”
it’s because the reality is that all materials have impacts, and it doesn’t just matter what material one uses, it also matters how that material is sourced, applied, and re-circulated.”
Sourcing is an important consideration in the debate, she says.
“Conventional plastic comes from non-renewable fossil fuels, while paper comes from renewable biomass. At face value, this seems to favour paper – but that advantage is quickly tempered by concerns about deforestation, forest degradation, loss of biodiversity, and the growing environmental and social impacts of industrial tree plantations. To realize the renewable promise of paper, it must be sourced and manufactured responsibly, with careful attention to protecting natural ecosystems and staying within planetary boundaries.”
Another consideration is end-of-life and circularity. Both materials can be part of circular systems, but achieving circularity in practice remains a challenge.
“While paper is often perceived as more recyclable, the real-world infrastructure, contamination rates, and quality degradation present ongoing hurdles for both materials. One critical distinction: the long-term environmental consequences of plastic pollutionr – particularly its effects on biodiversity and ecosystemsr – are still poorly accounted for in many decision-making processes.”
She concludes that, ultimately, the challenge goes far beyond choosing between two material types. The true challenge lies in rethinking our material systems altogether.
“We must do more with less, build better, more circular material systems that deliver real benefits to both people and nature and respect planetary boundaries. To reach this goal, we’re going to have to dig into the complexity of solutions and start thinking about how we put aspects of circularity like cascading value into practice.”
Rethinking packaging as a whole
Laura Smith, Project Manager in the Plastics Initiative at the Ellen MacArthur Foundation, also highlights the importance of assessing the environmental impacts of packaging materials in context, considering what the material is replacing, how it is designed, and the likely end-of-life pathways in a given region.
“In certain instances where existing packaging is difficult to recycle and prone to environmental leakage, paper alternatives that are recycled in local streams, regeneratively sourced, and significantly reduce negative impact if leaked may bring benefits. When and how is something we are currently exploring at the Ellen MacArthur Foundation.”
She points out that before turning to paper, we must ask if we can move away from problematic packaging formats entirely through elimination, reuse and product reformulation. “Material choice matters, but a circular economy asks us to rethink not just the packaging itself but more fundamentally how products are best delivered to users.”
In cases where packaging cannot be designed away nor be addressed via reuse system, paper may sometimes bring circularity benefits, especially if the alternative is challenging and expensive to recycle.
“This depends on the plastic being replaced: paper may be more likely to be recycled than flexible multi-material plastic in some regions, yet may be less likely to be recycled than other plastic formats such as PET bottles in many regions, as well as on the design of the paper packaging: coatings providing barrier properties must be designed to be technically recycled by local recycling streams, and the packaging must be considered sufficiently valuable by recyclers to be collected and accepted into mills.”
She adds that in addition to recyclability, paper can also be biodegradable and home compostable – if designed to meet the related
Laura Smith: “Material choice matters, but a circular economy asks us to rethink not just the packaging itself but more fundamentally how products are best delivered to users.”
standards. More work is required to explore whether that could minimize environmental harm in cases where packaging is likely to leak into the environment.
Paper can bring environmental trade-offs, including emissions, water use and sustainable sourcing concerns. It’s important to set the bar high to avoid replacing one problematic packaging with another.
“To avoid aggravating forest degradation and land use pressures, companies using paper should maximize recycled content, support the scaling of alternative fibres such as those made from agricultural waste, and follow strict procurement practices to protect ancient and endangered forests. Many environmental risks and mitigants must be assessed on a case-by-case basis,” she concludes.
FLUOZERO®:
YUTOECO’S PFAS-FREE SOLUTION TO OIL RESISTANCE IN MOULDED FIBRE PACKAGING
YUTOECO is an innovative, forward-looking sub-brand under YUTO, driven by the guiding principle of sustainability and offering solutions beyond packaging.
In this edition of our ‘In Conversation With…’ series, senior R&D engineer Jerome Zhang presents YUTOECO’s FluoZero® technology, said to protect moulded fibre against grease and oil without relying on PFAS.
What was the inspiration behind FluoZero®? Which market needs was it designed to address, and did you face any challenges?
As its name shows, FluoZero® is designed to ensure that products contain no fluorinated compounds, namely PFAS. PFAS are a class of “forever chemicals” that have been widely confirmed by research to pose environmental risks and human toxicity.
In February 2024, the U.S. FDA announced a complete ban on oil-repellent agents containing PFAS for food contact materials. Similarly, the EU’s PPWR
regulation came into effect this February, setting restrictions on PFAS content in food contact materials starting from August 2026. This essentially signals the complete phase-out of PFAS-based oil-repellent agents.
However, many current PFAS-free solutions on the market either rely on plastic coatings that contradict the EU’s policy to reduce single-use plastics or wax-based agents, which have very limited oil-resistance temperature ranges.
We’ve long hoped for a product that is fully bio-based, biodegradable, and highly oil-resistant, and so have our clients. Unfortunately, we couldn’t find a ready-made solution that met all these needs. As a result, we had no choice but to develop one ourselves.
Could you outline the process of manufacturing FluoZero® packaging?
Certainly. FluoZero® is not a simple additive that can just be mixed into traditional moulded fibre to achieve the desired effect. In fact, its production process involves three critical steps:
First, we developed a unique method to efficiently extract active components from various types of agricultural waste. Then, using proprietary technology, we bond these components with paper fibres, transforming the original interwoven fibre network into a dense barrier layer that effectively blocks oil penetration.
Finally, in order for these enhanced fibres to be used on existing moulded fibre production lines, the manufacturing process must be adjusted to ensure the retention of active ingredients and the quality of the final product.
What kinds of packaging products can FluoZero® make? Which industries does it best serve?
Currently, the most popular application of FluoZero® is still in the foodservice packaging industry. However, during our R&D process, we discovered that this technology has several additional performance features.
For example, in addition to being oil-resistant, it also shows strong resistance to chemical dyes. As a result, we partnered with another company to develop a hair dye packaging solution using FluoZero® technology. We believe this technology holds great potential in the personal care industry as well.
Moreover, we found that FluoZero® can significantly enhance the strength of moulded fibre packaging. After applying this technology, product thickness was reduced by 8%, while bending stiffness increased by 107% and bursting strength improved by 146%. This means that consumer packaging can be made lighter and more carbon-efficient without compromising on protection performance.
How does FluoZero® withstand so many different temperatures where other products on the market cannot, and what other performance-related benefits does FluoZero® unlock?
In my opinion, many PFAS-free solutions currently on the market do not fully meet all the key requirements, which is why I refer to them as “regrettable substitutes”.
For example, the existing additives used in moulded fibre solutions have limitations, such as temperature restrictions and short oil-resistant durations. Moreover, these additives are fossil-based and therefore not entirely environmentally friendly.
As for surface coating solutions, they may contain plastics and are often relatively expensive.
FluoZero®’s active components are highly stable across a wide range of temperatures, providing excellent oil resistance – up to 220°C for over 4 hours. Even in low temperatures around 4°C, its performance remains unaffected. This means FluoZero®-treated products can be used for both microwave and oven heating, as well as refrigerated storage.
In addition, FluoZero® is made from 100% bio-based, biodegradable materials. It truly achieves the optimal balance between performance and environmental sustainability.
Which certifications does FluoZero® have so far, and are any further certifications being pursued?
FluoZero® has already received USDA certification as a 100% bio-based material, as well as DIN CERTCO certification for >85% bio-based content – with 85% being the highest rating level under the DIN CERTCO system. Additionally, FluoZero® is certified compostable by both the EU and the U.S. BPI (Biodegradable Products Institute).
What’s next for FluoZero®?
As a matter of fact, we have already optimized our process to make a product with better performance than the existing FluoZero®, which we call FluoZero® Pro.
As mentioned in the previous introduction, FluoZero®’s high barrier performance is not solely dependent on the material itself, but rather the result of coordinated processes at every stage. By further refining these processes, we are looking forward to the mass production of the pro version, which can also enable broader application scenarios.
To learn more about YUTOECO’s FluoZero solution, visit www.yutoeco.com/ yutoeco-unveils-fluozero-the-pfas-free-greaseproof-revolution-in-moldedfiber-food-packaging_n148
Jerome Zhang - YUTOECO’s senior R&D engineer
HOW SUSTAINABLE CHEMISTRY DRIVES THE CIRCULAR ECONOMY FOR PACKAGING
In this edition of our ‘In Conversation With…’ series, Lisa Clark, VP Marketing & Sustainability –Packaging Technologies at Archroma, walks us through the ways chemistry can replace fossil materials while improving a pack’s performance, extending its lifespan, and enhancing its recyclability or compostability.
Firstly, how would you define sustainable chemistry, and how does it apply to the packaging industry?
Sustainable chemistry aims to replace traditional fossil-based materials with biodegradable, compostable or recyclable alternatives. It is the development and application of chemical solutions that enable high-performing, environmentally responsible packaging that minimizes the impact across the entire value chain – from raw materials to end-of-life recyclability.
The role of chemistry in fibre-based packaging production is often underestimated, but without it, there would be no packaging, sustainable or otherwise. Chemistry may make up a small percentage of the total package, but it can deliver more than 90% of the functionality.
Sustainable chemistry is all about the design, manufacture, and use of chemicals in a way that reduces the negative impact on the environment and which, therefore, enables circularity. It underpins everything from raw material selection to end-of-life recyclability, playing a fundamental role throughout the entire lifecycle of a package – from pulp to paper, to package, and back again.
We call it the ‘invisible force behind circular packaging’. At Archroma Packaging Technologies, driving the packaging industry towards a circular model sits at the heart of everything we do.
On that note, can you give us an overview of the contributions that sustainable chemistry can make to the circular economy?
chemistry plays a pivotal role in enabling and accelerating the circular economy particularly in industries like packaging.
At its core, circularity aims to eliminate waste and keep materials in use for as long as possible, imitating natural systems where nothing is wasted.
Chemistry underpins this by making materials perform better, last longer, and recycle more efficiently. From the moment raw fibres are pulped to the point they are reprocessed after consumer use, sustainable chemistry is active at every stage of the value chain. It strengthens recycled fibres, enhances barrier properties without using harmful substances like PFAS, and ensures adhesives and coatings are both effective and environmentally responsible.
One of chemistry’s standout contributions is the development of PFASfree, water-based barriers and adhesives that can replace plastic films in packaging. These innovations maintain the necessary protection for food and other sensitive products, while allowing the materials to be recycled or composted – essential for circular packaging.
Beyond technical performance, chemistry also solves logistical challenges. For example, fibre and water quality varies across regions; localized, tailored chemical formulations allow manufacturers worldwide to achieve consistent packaging quality while using locally sourced materials. This is critical for scaling circular solutions globally and reducing overall carbon footprint impact across the value chain.
What implications does sustainable chemistry have for the functionality and performance of a pack?
Sustainable
Lisa Clark
Chemistry fundamentally influences the functionality and performance of packaging, and we help to ensure that environmental responsibility doesn’t come at the expense of efficacy.
More sustainable chemistry not only preserves but often enhances the performance of packaging – delivering durability, protection, aesthetic quality and regulatory compliance while enabling recyclability and reducing environmental impact.
From a functional perspective, chemistry provides critical properties such as moisture, oil and grease resistance, which are essential for food and consumer goods packaging. Take our water-based, PFAS-free barrier coatings like Cartaseal®, for example; they ensure the integrity of packaging in conditions where they’ve been exposed to elements such as water, moisture, oil and grease, while also ensuring the packaging remains recyclable and compostable.
Through functional chemistries like fibre replenishers, crosslinkers and charge modifiers, sustainable chemistry can also restore and even enhance fibre strength, allowing recycled fibres to perform more like virgin fibres through multiple recycling loops. This significantly extends material lifecycle and improves structural integrity.
What about safety concerns? Is this solution suitable for food-grade packaging or reusable solutions?
Our chemistries are not only suitable for food-grade packaging solutions; they are specifically designed to meet the highest safety standards. At Archroma Packaging Technologies, we ensure rigorous compliance with food and safety regulations.
Product stewardship is paramount to us and we have an entire team proactively engaging at the front end of our innovation efforts to ensure we are developing safe and responsible products.
Our range of products including barrier coatings, adhesives, colourants, and process chemicals meet strict safety standards for food contact, and many of our solutions are compliant with global and local regulations including the FDA (USA), BfR (Germany), MERCOSUR (South America), as well as eco-labels such as the Nordic Swan, EU Flower, and Blue Angel.
In addition, our colourants and coatings are free from heavy metals and harsh solvents which are typically restricted or banned in food-contact applications.
And what impact does it have on costs? Is sustainable chemistry accessible for SMEs and start-ups?
Initially the transition to more sustainable chemistry can seem quite daunting; however, the long-term savings and strategic advantages can make sustainable and water-based chemistries accessible for SMEs and start-ups. For example, chemistry can enhance fibre strength, durability and recyclability, which enables greater use of recycled content and reduces the dependency on virgin fibres, which are typically more expensive. This, in turn, extends the lifecycle of packaging materials and lowers waste generation.
Investing in compliant PFAS- and VOC-free chemistries now will help SMEs avoid future costs associated with potential regulatory risks or prod-
can immediately demonstrate their alignment with consumer values, which is likely going to have a positive impact on overall brand perception.
All of this is paving the way for SMEs and start-ups to operate in a competitive and sustainability-driven market.
Where
is
sustainable chemistry going next, and are there any challenges we need to overcome?
As with any industry, there will always be challenges to overcome. For sustainable chemistry, cost and scalability can sometimes be barriers to adoption. However, with greater collaboration through the supply chain to align goals, pool R&D resources and scale innovations more efficiently, we hope that this will ease such pressures.
Working towards this goal, Archroma Packaging Technologies is part of initiatives such as the Sustainable and Alternative Fibers Initiative (SAFI) which is focused on ‘researching, developing and utilizing alternative fibres to manufacture a myriad of sustainable products’. By joining initiatives like SAFI, we are working with other global entities to drive innovation and progress. Regulatory uncertainty is also a challenge globally. Regulations like the EU’s PPWR or Single Use Plastics Directive are evolving constantly, creating a moving target for R&D teams, meaning that companies must stay agile and future-looking. Similarly, the recycling infrastructure is inconsistent around the world – if a package is recyclable or compostable in one market, it may not be processed correctly in another – so more collaboration and alignment across countries is absolutely needed.
With this in mind, Archroma Packaging Technologies is actively engaged in the 4Evergreen Alliance and Sustainable Packaging Coalition, whose various collaboratives bring the entire value chain together to solve these challenges. Bottom line, collective effort is essential to drive this forward. It isn’t just commendable action; it is crucial to develop high-performing packaging that safeguards our planet for future generations.
There is no doubt that we will continue to see more bio-based breakthroughs, with new material innovations creating packaging with near-zero carbon footprints. In fact, we are working on some exciting developments, which we hope to share information on towards the end of the year.
Visit www.archroma.com/packaging-technologies/ to learn more about Archroma Packaging Technologies’ sustainability-minded solutions.
A LOOK INSIDE MONDI’S ACQUISITION OF SCHUMACHER PACKAGING
Earlier this year, Mondi completed its acquisition of Schumacher Packaging’s assets in Western Europe. In this edition of our ‘In Conversation With…’ series, we touch base with Markus Gärtner, CEO Corrugated Packaging at Mondi, to learn more about the implications for the companies, customers, and industry as a whole, and what we can expect to see going forward.
For our readers who might be unfamiliar, walk us through Mondi’s acquisition of Schumacher Packaging. What benefits or services will customers receive from this expansion?
At the beginning of April, twelve Schumacher Packaging sites across Germany, the UK and the Netherlands joined Mondi Group. These sites produce corrugated solutions and solid board which is an ideal strategic fit for our business and increases our corrugated converting capacity by over one billion square metres. It has been a real pleasure getting to know our new colleagues – we have a great cultural fit and the integration is already going very well.
The acquisition expands Mondi’s corrugated footprint in Western Europe providing customers with an even broader portfolio of packaging solutions and superior service. The high-capacity plants of Mondi Ebersdorf and Mondi Greven are part of this expanded network, and we are seeing firsthand how the ‘best of both worlds’ expertise from Mondi and Schumacher is adding real customer value.
In this dynamic world, we all know the importance of a reliable service. At Mondi, our integrated value chain – from in-house containerboard production to advanced converting capabilities and packaging design – allows us to offer consistent product quality, innovative packaging solutions and a responsive service. This end-to-end expertise ensures that we can support our customers with tailored, efficient and sustainable packaging, every step of the way.
How does this acquisition fit with the broader consumer and customer trends in our industry?
Our latest Mondi Group consumer research finds that 8/10 consumers across Europe demand sustainable or recyclable packaging and 4/10 consumers will avoid shopping with retailers where there is packaging waste. Our strategy is fully aligned with such long-term trends as we are growing our portfolio of sustainable packaging solutions. Our customers want to solve many of the world’s most demanding challenges, such as building circular solutions, tackling food waste and increasing material efficiency.
Another trend we see is that customers are looking for suppliers with a broad portfolio and multi-material expertise – because they want to improve the sustainability of their packaging without compromising on product protection. This includes a diverse range of corrugated and solid board grades as well as flexible packaging, with tailored solutions meeting both environmental and performance needs.
For a long time, e-commerce was synonymous with shipping paperboard boxes – today, a broad spectrum of innovative, sustainable solutions is available, from standard shipping formats such as our recyclable MailerBAGs, solid board envelopes, kraft paper, containerboard and corrugated solutions to premium designs. Also, digital printing is becoming more and more important as it can increase operational efficiency. With in-house digital, offset and flexo printing, we now cover a wide spectrum of needs.
Following on from that, how would you say the acquisition helps customers improve their sustainability?
The acquisition strengthens the scale of recyclable, fibre-based solutions we can offer e-commerce and FMCG companies where sustainable fit-forpurpose packaging is a priority.
As you may know, Mondi is an industry leader with our MAP2030 sustainability framework, and our efforts are recognized by leading independent sustainability benchmarks.
Our product innovation teams enjoy the daily challenge of helping our customers reduce their environmental impact through smart packaging design and recyclable materials. If you have a challenge you want to share – such as how to replace expanded polystyrene (EPS) with a more sustainable solution – we’d love to hear from you!
What outcomes do you expect to see as you expand into the Western European market?
Western Europe is a very developed market with high standards and high expectations, especially when it comes to sustainability, service and product performance. Germany is Europe’s largest packaging market and
expanding our presence here brings us closer to customers and allows us to offer a fast and reliable service.
With this acquisition we are now among the top corrugated packaging manufacturers in Europe and our aim is to continue building long-term relationships with our customers. We want to be more than just a supplier – we aim to be a strategic partner with both international scale and local insight.
What differences do you see among generations in terms of packaging trends?
Our annual survey of 6,000 consumers across Europe gives us many insights that drive our innovation. For example, our latest results found that 71% of Generation Z consumers say that unboxing heavily influences their purchasing decision, compared to half for the Boomer generation. In fact, 59% of all consumers say a poor unboxing experience would put them off buying again.
This is one example of where our industry needs to keep evolving and our product innovators are working on designing solutions that are not just for safe delivery but also support a fantastic brand experience. In fact, many of our best ideas come during our customer co-creation workshops which take place at our ThinkBox innovation centres where generational needs are of course part of the design equation.
With all this in mind, what are Mondi’s next steps?
Right now, we’re focused on integrating our teams and systems, and making sure customers benefit from our expanded offering and services across Europe.
Longer term, our strategy hasn’t changed: being a leading partner for packaging solutions that meet the evolving needs of our customers – from improving sustainability and recyclability to enhancing efficiency, product protection and brand impact. We’re committed to working closely with our customers to co-create smart, fit-for-purpose packaging that supports their transition to a circular economy, while also delivering on performance, cost-effectiveness and consumer expectations.
To learn more about the acquisition, Mondi’s expanded product portfolio, and the services Mondi supplies, visit: mondigroup.com/scaling-up
Markus Gärtner
DIGITALIZATION AND STANDARDIZATION: THE KEYS TO REGULATORY COMPLIANCE?
In this edition of our ‘In Conversation With…’ series, Laura Ott, head of Customer Development at PreZero Sustainable Packaging, explains how digitalization and standardization can help businesses keep on top of evolving legislation – and how PreZero can help.
In your experience, what challenges do companies face with regulatory compliance in the packaging sector?
“Too much, too soon, too new.” That’s how many businesses would describe the current regulatory climate. The Packaging and Packaging Waste Regulation (PPWR) is the most comprehensive overhaul of EU packaging law to date – but it’s only one piece of the puzzle.
Companies are also grappling with the EmpCo Directive, national plastic taxes, eco-modulation schemes, littering fees, and even the Deforestation Regulation. The pace and volume of change are overwhelming, especially for organizations without specialist resources.
The PPWR alone will require entirely new declarations of conformity and technical documentation for all packaging by mid-2026. But perhaps the biggest challenge is that compliance can’t be siloed.
It’s no longer a task for just the packaging or legal teams. Product management, marketing, and even corporate strategy are directly impacted – requiring cross-functional coordination that many businesses aren’t yet set up for.
So it’s not just a legal or technical challenge – it’s an organizational one?
Exactly. These regulations go to the core of how products are designed, labelled, marketed, and even priced. Meeting them requires not only new technology, but new ways of working.
How can digitalization help to overcome these challenges?
Digital packaging data management is quickly becoming a necessity – not a nice-to-have. Take the PPWR: by mid-2026, companies must prove that their packaging is recyclable, minimized, free of substances of concern, and – if plastic – contains a specific share of recycled content.
But it’s not enough to simply meet these criteria. You have to report on them fastidiously, in a declaration of conformity backed by technical documentation.
And that’s where it gets complex. Let’s say you manufacture shampoo in a plastic bottle. To assess recyclability, you need data from the bottle supplier, the label manufacturer, the cap producer, and then aggregate those inputs into a single, compliant packaging unit. Compliance isn’t assessed per component, but per complete packaging system.
Managing this with PDFs and spreadsheets may work for one SKU. But even a modest product portfolio quickly turns that process into a versioncontrol nightmare. For SMEs and multinationals alike, digital tools are the only scalable solution.
With all these changes on the horizon, what practical steps should companies take now to get ready?
First, take stock of what you already have. Many companies assume they have more packaging data than they actually do.
A structured gap analysis is the essential starting point: How much of the information required for recyclability assessments or other aspects of a declaration of conformity is already available? And how much is missing, outdated, or siloed?
The next step is to put the right software in place. Without a centralized system to manage packaging specifications, it becomes nearly impossible to track key metrics, generate compliance documentation, or support broader sustainability reporting in a reliable way.
Finally, it’s about integration. Your packaging data system shouldn’t be a standalone tool. It needs to connect to your ERP, your PIM, and – critically – your supplier workflows.
Our best-practice recommendation is to make packaging data part of your standard business exchanges: whenever you send or receive goods, the relevant packaging specifications and compliance data should be attached by default. That’s the level of readiness the new regulatory environment demands.
PreZero is known primarily as a European waste and recycling company. What role do you play in helping businesses prepare for regulatory change?
We’re far more than a recycling company – we see ourselves as a circular economy enabler. Many of our innovations have grown directly out of the needs of our parent organization, the Schwarz Group.
For example, we’ve established one of Germany’s leading packaging recovery schemes, now the second largest in the country. We’ve helped transform waste streams from a cost factor into a value driver, and we’ve built scalable systems for reusable transport packaging, such as pooled pallets.
Now, like everyone else in the industry, our retailers, Lidl and Kaufland, need to get their packaging portfolios ready for PPWR. That’s why we’ve partnered with leading specialists and developed a comprehensive service offering for packaging compliance and sustainability – one we’re now making available to the wider market.
What sets us apart is our operational perspective. We’re not a classic consultancy. We come from hands-on experience. We operate some of the most advanced sorting and recycling plants in Europe. When we talk about
recyclability, we’re not speaking theoretically – we’re speaking from the reality of what happens on sorting lines and recycling processes.
You’ve outlined the challenges and the strategic response. How exactly can PreZero support companies on the path to compliance?
It all starts with digitalization. That’s why we launched PreZero SPOT – a software solution developed in partnership with Packaging Cockpit and their parent company Circular Analytics, renowned for their expertise in the environmental assessment and optimization of packaging.
SPOT is a digital platform for packaging specification management, optimization, and conformity checks. In short: it delivers exactly what’s needed to prepare for regulations like the PPWR.
And we’ve made it easy to try. Companies can explore SPOT free of charge at spot.prezero.com and see for themselves how it can support their packaging workflows.
But SPOT is only the beginning. Our broader offering is designed to take companies all the way to full compliance – and beyond. We call it the SPEAR framework:
S
– Study: Our experts help you interpret the PPWR and related legislation in the context of your actual packaging portfolio – cutting through the complexity and clarifying how exemptions and thresholds apply.
P – Prepare: We analyze your current packaging portfolio and map it against upcoming regulatory requirements – identifying where you’re already on track and where adjustments are needed. This isn’t just about highlighting problems; it’s about creating a clear, prioritized plan of action that reflects your business reality and timelines.
E – Enhance: Our packaging engineers work with your team to define optimal solutions – balancing compliance, cost, sustainability, and consumer expectations.
A – Act: We support implementation through supplier scouting, solution validation, and even hands-on project management where needed.
R – Report: We help you track your progress and communicate it effectively – advising on claims, marketing messages, and reporting KPIs that resonate with customers.
And if you prefer to manage most of this internally? Even better. We’re here to support where it counts – without pushing unnecessary consulting or generic solutions. It’s about enabling your teams, not replacing them. To learn more about the PreZero SPOT platform, visit: prezero-international.com/leistungen/sustainable-packaging/sustainable-packagingoptimization-tool
COVERIS & RECOVER: DRIVING CIRCULARITY IN A CHANGING LEGISLATIVE LANDSCAPE
In this edition of the Spotlight, Coveris explains how its ReCover recycling business is helping to advance compliance with legislation and bolster the company’s capabilities for sourcing, processing and recycling plastic waste.
Driving circularity and compliance with EPR & PPWR
As the packaging industry navigates an evolving regulatory landscape, Coveris remains at the forefront of sustainable innovation with its dedicated recycling business, ReCover. With the UK’s Extended Producer Responsibility (EPR), the recently issued Recycling Assessment Methodology (RAM) tool and the EU’s Packaging and Packaging Waste Regulation (PPWR) redefining industry obligations, ReCover plays a pivotal role in advancing Coveris’ No Waste vision and compliance with legislation.
A proactive approach to compliance
Under EPR, companies placing packed goods on the market bear the lifecycle costs of their packaging, including collection, sorting, and recycling. The UK’s scheme introduces modulated fees, meaning businesses will be incentivized to design packaging that is easier to recycle. Similarly, the EU’s PPWR mandates that all packaging be recyclable by 2030, with clear targets for minimum recycled content in plastic packaging.
ReCover directly aligns with these legislative shifts by bolstering Coveris’ capabilities in sourcing, processing, and recycling plastic waste, helping to close the packaging loop. By increasing the availability of high-quality recyclate, ReCover provides a new source of recycled content for Coveris to integrate into its packaging solutions. Coveris’ packaging innovation is centred on sustainable solutions compliant with both EPR’s recyclability requirements and PPWR’s mandated recycled content targets.
Expanding recycling capacity to meet market needs
With ambitious goals to increase plastic recycling capacity to 50,000 tonnes by 2026 and 90,000 tonnes by 2030, ReCover is scaling up efforts to support both Coveris and its customers in meeting legislative and sustainability demands. This includes pioneering recycling methods to maximize material recovery from different film waste streams. By doing so, ReCover not only supplies Coveris with high-quality recyclate but also contributes to broader industry efforts to enhance recycling infrastructure.
Pioneering de-inking technology
Launched in 2023, Coveris’ ReCover facility in Louth, UK, employs pioneering de-inking technology to remove ink from printed polyethylene films, transforming packaging waste into high-quality recycled PE resin, known as ReGen.
Partnering to advance the circular economy
Further supporting its No Waste sustainability strategy and ReCover mission to keep plastic circular, Coveris has a strategic partnership with leading environmental service provider, Interzero. Formed to advance the circular economy, the partnership provides post-consumer waste for ReCover to recycle and produce high-quality recycled resins. With this partnership, Coveris and Interzero can offer full closed-loop solutions.
Delivering EPR and PPWR-ready solutions
The innovative ReCover model supports Coveris’ development of packaging that meets the highest sustainability criteria. Coveris’ innovation of award-winning mono-material structures such as its MonoFlex range ensures packaging is more readily recyclable within existing waste management systems. Complemented by integrating increased levels of recyclates in its plastic products, Coveris is well-positioned to align with EPR’s recyclability incentivized modulated fee structure and comply with PPWR’s minimum PCR content regulations.
Shaping the future of sustainable packaging
By investing in innovative recycling technologies via ReCover, forging partnerships within the supply chain and a continued focus on environmentally responsible packaging and operations, Coveris is taking a leading role in sustainability within the sector, whilst empowering its customers to meet their own commitments. With the No Waste strategy at the heart of Coveris’ business, ReCover exemplifies how proactive leadership and ambitious change can drive meaningful environmental progress whilst meeting legislative responsibilities.
Visit us at FachPack, hall 4 booth 232
UNLOCKING THE FUTURE OF PACKAGING WITH FIBRE-BASED MATERIALS
In this edition of the Spotlight, SWM International details its fibrebased packaging solutions including plastic film and foil alternatives, botanicals such as hemp and specialty papers for food contact and medical packaging.
INconsumer consciousness have created a critical demand for innovative materials. SWM International is at the forefront of this shift, offering high-performance fibre-based packaging solutions that blend environmental responsibility with technical precision.
Driving sustainable innovation
As global brands face increasing pressure from regulators and consumers to reduce their environmental footprint, fibre-based materials have emerged as a compelling alternative to traditional packaging like plastic films and foils. SWM International answers this demand through the development of ultra-lightweight, recyclable paper solutions manufactured from renewable resources.
What sets SWM apart is its commitment to a science-driven approach. We don’t simply replace plastic with paper, we reimagine paper itself. Through advanced fibre engineering, SWM ensures that its materials meet strict performance criteria for barrier properties, printability, strength, and compliance with food and medical safety standards.
Beyond wood pulp: pioneering botanical-based innovation
While wood pulp remains a key component of SWM’s portfolio, the company is pushing boundaries by incorporating non-wood botanicals such as hemp, flax, and agricultural by-products. These alternative fibres not only offer reduced environmental impact through lower water usage and faster renewability, but also bring distinct functional benefits to packaging applications. By embracing a broader palette of natural inputs, SWM is helping brands achieve lifecycle sustainability goals. This diversified material base also allows for better regional sourcing and adaptation to local agricultural ecosystems.
SWM’s portfolio includes an array of specialty papers tailored for food contact, luxury wrapping, medical packaging, and other niche applications. With customizable parameters such as grammage, translucency, porosity, and coating compatibility, SWM equips brands with the flexibility to fine-tune packaging aesthetics and functionality.
What’s more, the company’s collaborative R&D model enables codevelopment with clients. This approach accelerates innovation cycles and ensures that materials are aligned with specific supply chain and end-user requirements.
Strategic value beyond material supply
In a market where packaging decisions directly influence brand equity and compliance readiness, SWM positions itself as more than a supplier. It serves as a strategic innovation partner, providing support and regulatory expertise alongside its materials portfolio.
With legislation such as the EU Packaging and Packaging Waste Regulation (PPWR) and Extended Producer Responsibility (EPR) schemes coming into sharper focus, working with a forward-thinking partner like SWM helps businesses stay ahead of compliance curves while elevating their sustainability narratives.
Discover more in SWM’s digital portfolio
To further explore SWM’s sustainable material strategies and application possibilities, readers are encouraged to consult the company’s latest Product Differentiation e-book. It provides a detailed look at the composition, performance, and environmental advantages of SWM’s fibre-based solutions.
To view the Product Differentiation e-book, visit: https://it4v7.interactivdoc.fr/html/inspiring_with_natural_and_smart_solutions_1004/
PIOVAN LAUNCHES SMARTFORESIGHT: THE PREDICTIVE MAINTENANCE SOLUTION THAT HELPS PREVENT UNPLANNED DOWNTIME
Unplanned equipment failures cost manufacturers millions annually. Production lines stop, deadlines slip, and profits evaporate when critical dryers fail without warning.
SmartForesight transforms maintenance from reactive to predictive. Piovan’s intelligent monitoring solution provides predictive analysis of
GN, GP, and GMP dryers, detecting abnormal behaviour before the fault occurs. Cloud-based edge technology delivers real-time alerts directly to Piovan Service team and yours. The system’s customizable monitoring capabilities allow both predictive control and precise monitoring to be tailored to specific customer requirements to meet various customer needs and operational realities.
Maximize uptime, prevent costly breakdowns, and optimize ROI through proactive maintenance scheduling. IEC 62443-3-3 cybersecurity compliance ensures data. Monthly performance reports and direct access to Piovan experts accelerate operational improvements.
SmartForesight integrates seamlessly with existing systems. Extended warranties, priority field service, and comprehensive training programs complete this game-changing solution.
Ready to prevent unplanned downtime? Discover how SmartForesight can transform your operations at PiovanGroup’s booth C6-380 at drinktec 2025
ARYADEW: REVOLUTIONARY ENERGY-EFFICIENT DEHUMIDIFICATION SOLUTION DELIVERS 70% COST SAVINGS
Rising energy costs plague plastic manufacturers worldwide, impacting profitability while demanding consistent production quality.
AryaDew by Thermal Care revolutionizes mould cabin dehumidification through closed-loop cooling cycle technology. This breakthrough system delivers up to 70% energy savings compared to conventional solutions, ensuring constant dew point control for optimal production environments.
The compelling business case is clear: payback periods under 2 years make AryaDew an immediate competitive advantage. Designed for PET preform production, high-speed injection molding, blow moulding, and injection blow moulding, the system prevents mould condensation while optimizing production cycles. Smart Adaptive Fans (SAF) technology maintains
consistent performance through variable-speed, high-pressure ventilation.
Industry 4.0 compatibility enables seamless integration into existing production systems without water pre-cooling requirements. Simplified installation reduces operational costs while minimal maintenance maximizes uptime.
Transform your production efficiency today. Come visit us at drinktec 2025 at Piovan-
Group’s booth C6-380 to discover how AryaDew’s revolutionary technology can reduce your operational costs while enhancing product quality and environmental sustainability.
LABEL INNOVATION – FROM SUSTAINABILITY TO AUTOMATION
Jade Grace, Managing Director Labelexpo Global Series and Andy Thomas, Strategic Director, Labelexpo Global Series discuss trends and developments in the label industry and what visitors can expect from Labelexpo Europe at its new venue in Barcelona this September.
Packaging Europe: What are the key themes of this year’s Labelexpo Europe, and how do they reflect the current trends in the global labelling and packaging industry?
Jade Grace: Labelexpo Europe 2025 has been carefully designed to reflect the evolving landscape of the global label and package printing industry. This year’s edition is covering the full range of package printing and converting technology for labels, flexible packaging and folding cartons with a strong focus on sustainability and automation.
These themes are in synergy with the current industry’s direction of travel, particularly the increased attention to sustainable solutions, the need for automation, and the growing convergence of inline and digital printing technologies between labels, flexible packaging and folding cartons.
PE: Can you share some of the most exciting technology launches or innovations debuting at this year’s show? Which ones do you think will have the biggest impact?
Andy Thomas: Particularly interesting at Labelexpo Europe 2025 is the resurgence of flexo technology, with the development of wider presses for package printing applications, more automation and more integration with digital workflows.
There will be a strong presence of mid-web (26in/670mm) flexo presses, many seen in Europe for the first time. The wider format allows more efficient production of flexible packaging, shrink sleeve labels and in-mould labels as well as opening up new possibilities in high-volume wet-glue labels.
The growing automation of flexo also impacts the many hybrid flexo-inkjet presses on the show floor, combining with higher inkjet engine speeds to create far more powerful inline systems.
In digital standalone presses we see a trend towards faster print speeds, increased print resolution and the advance of water-based inkjet, with both Canon and Epson showing new presses.
The trends towards automation and digital integration also impacts converting and finishing machinery, and visitors can expect to see advances in digital embellishment, laser die cutting and remote set-up of varnishing,
Fira Gran Via, Barcelona, Spain
semi-rotary die cutting and slitting knives from a printed QR code. Smart labeling and packaging are also heavily featured at the show, particularly RFID label manufacturing and encoding lines.
PE: Sustainability continues to dominate packaging conversations. How is Labelexpo showcasing advancements in sustainable label ling materials, adhesives, and processes?
JG: Labelexpo Europe 2025 is placing sustainability at the heart of the event. The Pulse Arena, located in Hall 7 – Stand 7B27 will feature expert presentations on the EU’s PPWR (Packaging and Packaging Waste Regula tion) on the first day of the show. Presentations over the next three days on Folding Cartons, Flexible Packaging and Automation all contain a strong sustainability focus – for example the development of coated monomaterials to replace laminations and automating the collection of carbon footprint data across the labels supply chain.
the full range of sustainable technologies at the show.”
Labelexpo Europe 2025 will also feature a PPWR trail, which showcases the full range of sustainable technologies at the show. These products include washable label adhesives which allow PS labels to be cleanly removed from plastics and glass containers; primers which allow UV inks to separate from shrink sleeves and primers which delaminate multi-layer flexible packaging; automatic, real time reporting of carbon footprint data from running machines and much more. Expect also further progress in moving linerless labels into prime (primary) label applications.
PE: Converters are under pressure to do more with less – less waste, energy, and time. Are there particular solutions or workflows on display that tackle operational efficiency and lean manufacturing?
AT: In addition to supporting sustainable practices, automation is, of course, a crucial tool to help businesses address labour shortages and other challenges. MIS (management information systems) suppliers, prepress systems developers and machine manufacturers are working together to automate the workflow from order input to job management, factory planning, quality assurance and final delivery.
Two partnerships at the show demonstrate this very well: Lemu Group, ETI and Martin Automatic demonstrate a fully automated production line from raw material to finished reels integrated with robotic packaging; while the Label Trail brings together Esko, CERM, Avery Dennison, Kurz, GM and
CarbonQuota to demonstrate a networked production system including QR codes, digital metallization, brand security and automated collection of carbon footprint.
Labelexpo Europe 2025 also features a Label Academy Automation Master Class, a dedicated session on automation in label production, focusing on the increasing role of automation across machines and processes, including AI and robotics.
PE: Labelexpo is now also including folding carton exhibitors. What prompted this shift, and what can visitors expect?
JG: The increased emphasis on folding carton technology follows a natural industry evolution based on converging technologies and market demand: over 25% of visitors to Labelexpo Europe 2023 registered interest in folding carton technology.
Labelexpo has always been the home of inline and digital print and converting technologies, and these same technologies are now set to disrupt the traditional multi-process offset folding carton industry. We have already seen this happen to flexible packaging at Labelexpo, with label converters working with press and materials suppliers to create a wholly new category of short run, value-added printed packaging based on inline flexo and digital technology.
Andy Thomas:
“In addition to supporting sustainable practices, automation is, of course, a crucial tool to help businesses address labour shortages and other challenges.”
This natural evolution is already felt on the show floor, with around onefifth of all Labelexpo Europe exhibitors currently supplying technology to the folding carton industry.
Canon-Edale will demonstrate the first inline flexo folding carton line seen at a Labelexpo show. The Edale CartonLine UV flexo press incorporates turnbar, cold foil and laminating stations and inline flatbed die cutting.
PE: In conclusion, what are your expectations for this upcoming Labelexpo in its new location, Barcelona?
AT: Marking a historic milestone in its 45-year legacy, Labelexpo Europe 2025 is set to deliver its largest show ever, welcoming over 650 industry suppliers and expanding floor space by an impressive 15% compared to the 2023 edition.
The event will offer more opportunities for networking, and more live demonstrations of machinery and automation in action than any previous show. Our industry has evolved dramatically in recent years and so has Labelexpo.
Most importantly, Labelexpo Europe 2025 continues to be the leading platform where industry professionals can collectively address transformative challenges, particularly sustainability initiatives and the ongoing convergence of technologies that are reshaping the sector.
LABELEXPO EUROPE 2025 - INNOVATION PREVIEW
ACTEGA - QUALITY, FUNCTIONALITY AND SUSTAINABILITY
ACTEGA, manufacturer of specialty coatings, inks, adhesives, sealants and compounds for the print and packaging industry, will showcase its latest solutions, partner and customer collaborations and advanced labelling technologies at Labelexpo Europe 2025 (booth 3D41). Combining quality, functionality, and sustainability, these innovations demonstrate how ACTEGA is helping brands achieve their environmental and performance goals.
At the event, visitors will see live demonstrations of ECOLEAF, ACTEGA’s on-demand metallization technology, configured with the Gallus One Digital Press. With the motto “The new standard”, ECOLEAF has become the go-to solution for
sustainable metallic embellishments, helping converters and brand owners reduce waste and energy usage while delivering premium, eyecatching labels and packaging designs. Samples from several projects with industry frontrunners will be showcased during the event.
ACTEGA will also demonstrate Signite® – an award-winning labelling solution that combines ultra-thin, durable decoration with state-ofthe-art applicator technology. Visitors will find out about ACTEGA’s exclusive European, South and Central American partners for this solution, All4Labels, and see how this innovative ‘no label look’ sustainable decoration can be applied to glass and PET bottles.
DOMINO: DIGITAL PRINTING INNOVATIONS
Domino Printing Sciences (Domino), a global provider of advanced variable data printing solutions and digital printing technology, will unveil its latest digital printing innovations, including the new compact Domino N410 LED label press at Labelexpo Europe.
Domino will feature the new press alongside a comprehensive range of digital printing solutions at Hall 3, Booth 3E91, Fira Gran Via.
Live demonstrations will showcase the N410 LED label press, Domino’s proven N730i and N610i digital label presses, as well as K600i and K300 monochrome inkjet printers. Recent years have seen increasing demand from converters looking to expand their offering into digital printing appli-
AVERY
DENNISON:
ATLabelexpo, Avery Dennison will mark 90 years of “Making Possible” by showcasing how its materials science and digital identification solutions continue to unlock new value for customers at booth 3E61.
ACTEGA will also showcase its innovative coat ings product portfolio for pressure-sensitive labels, shrink sleeves, and in-mould labels. ACTEGA’s advanced coatings include gloss, matte, motion effects, and cutting-edge UV and LED coatings. With these products, ACTEGA empowers printers and converters to achieve exceptional aesthetics, functionality, and durability while addressing key technical challenges such as scratch resistance, slide angle, and adhesion.
For more info, visit www.actega.com
cations. Domino is pleased to support these businesses with the launch of the compact Domino N410 LED label press – allowing converters to take their first step into digital printing and benefit from the flexibility with low running costs.
“LED presses are versatile and enjoy increasing popularity because of their environmental benefits, helping converters save on energy costs and reducing waste,” explains Russell Weller, Head of Digital Products, Domino. “The N410 offers excellent value for converters looking to unlock new growth opportunities with a versatile digital solution, future-proofing their investment with LED inks, supported by Domino’s world-class service and global support network.”
More info: www.domino-printing.com
THE FUTURE OF PACKAGING INNOVATION
reuse materials more effectively, helping brands stay ahead of tightening legislation and rising consumer expectations.
The booth will offer a bold look into the next decade of innovation – from advances in circular packaging and intelligent labels to breakthroughs that will drive sustainability efficiency, shelf appeal and performance.
Avery Dennison’s Booth 3E61 will include: Helping customers navigate circularity
The booth will bring the science of packaging recyclability and material reuse to life, showcasing solutions for every packaging format. Visitors will see how innovations like label release technology make it possible to recycle and
Packaging that captivates on shelf and connects with consumers
A dedicated retail zone will spotlight packaging innovations designed to boost shelf appeal and drive consumer engagement, including the newest luxury materials from the Infinity and Sensorial Collections as well as demos featuring RFID and NFC solutions.
Powering visibility from source to shelf
An interactive display will show how RFID technologies deliver end-to-end transparency, enabling real-time tracking from production to point-of-sale and helping businesses optimize operations and reduce shrink.
Driving compliance and safety
Avery Dennison will present its latest functional material and RFID solutions for automotive and EV batteries. For the pharmaceutical sector, solutions are designed to improve patient safety and meet strict regulatory standards through improved product authentication and supply chain visibility.
