New tech tackles sticky problem in paper recycling

Adhesives used in paper and cardboard packaging, often referred to as 'stickies', pose a significant challenge to the recycling process. These materials can damage recycling equipment, degrade the quality of the final recycled paper product, and even lead to entire batches being rejected, according to scientists at NC State University. With paper being a highly recycled material in Europe, efforts are underway to address this issue, particularly in light of upcoming European Union regulations.

Stricter Regulations Drive Innovation

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A new Europe-wide regulation on packaging and packaging waste (PPWR) will take effect in August, requiring all packaging to be at least 70% recyclable by 2030, with a further increase to 80% by 2038. This legislation, alongside stricter German reporting and licensing requirements, is prompting companies to find alternatives to traditional adhesives. The German packaging industry, known as Packaging Valley, is at the forefront of developing these innovative solutions.

Adhesive-Free Sealing Technologies Emerge

Several German firms are exploring ways to seal paper packaging without relying on foreign materials like glue. The research organisation Fraunhofer initiated the PAPURE project in 2023, aiming to develop a laser-based heating process for adhesive-free sealing. This technology was showcased at the Interpack trade show in May, and Fraunhofer hopes to partner with an industry player to bring it to market within two years. Separately, engineering firm Hermann Ultraschall acquired rights in 2023 to develop a patented ultrasonic paper sealing technology, described as akin to welding. Both companies are in discussions with major market players for mass production.

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“"There are not really many paper sealing technologies without any foreign materials, so it's a great technology and we feel it's likely that we can bring it to market."”

Fabian Kayatz, Researcher Group Leader at Fraunhofer

Challenges and Solutions for Food Packaging

Implementing these new technologies presents challenges, including the need for manufacturers to potentially update or replace existing machinery designed for glue-based applications. Production speeds also currently lag behind traditional methods, although automated production is seen as a future development. Furthermore, not all paper materials are compatible with these bonding techniques. For food-grade packaging, which requires a barrier coating, Fraunhofer's laser technology has not yet found a solution. However, Henkel has launched a cold seal solution suitable for recyclable, barrier-coated paper, which is already being used for snack and confectionery products. Henkel also previously developed a heat seal solution that enabled brands like Regina to switch from plastic to paper for hygiene products.

Dr Arianna Savini, market strategy manager for paper packaging Europe at Henkel's adhesive technologies division, highlighted the systemic shift required, involving all supply chain players. She noted that the momentum is strong due to the PPWR deadline, making the transition to more sustainable and recyclable packaging a priority across the industry.

The Path Forward

The development of adhesive-free or easily recyclable sealing methods is crucial for meeting the upcoming EU targets and improving the environmental footprint of paper packaging. While challenges remain in machinery adaptation and material compatibility, ongoing innovation from companies like Fraunhofer, Hermann Ultraschall, and Henkel indicates a strong industry commitment to overcoming these hurdles and advancing sustainable packaging solutions.