New Technologies Aim to Eliminate Glue and Labels in Paper Packaging Recycling
German firms are developing innovative methods, including laser and ultrasonic sealing, to make paper packaging more recyclable and reduce reliance on traditional adhesives.
Three German companies are pioneering technologies to seal paper packaging without adhesives, addressing a significant barrier to paper recycling. Fraunhofer, Hermann Ultraschall, and Henkel are developing innovative solutions aimed at complying with stricter recycling regulations and reducing contamination from glues and labels.
The PAPURE project, initiated by the German research organization Fraunhofer in 2023, is developing a laser-based heating process for sealing paper. This method aims to bond paper without introducing foreign materials, which often hinder the recycling process. Fraunhofer researchers exhibited their work at the Interpack packaging trade show in May and are seeking industry partners to bring the technology to market. Fabian Kayatz, a researcher group leader at Fraunhofer, expressed optimism about the technology's potential, stating, "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." The project is expected to conclude in September, with a potential market launch within two years.
Meanwhile, engineering firm Hermann Ultraschall acquired the rights to a patented ultrasonic paper sealing technology in 2023. This process, described as akin to welding, is currently in discussions with major industry players for mass production. Michael Baumann, head of business development packaging at Hermann Ultraschall, noted the novelty of the innovation, saying, "One customer told me this is an innovation they have never seen before."
Despite the promise of these adhesive-free methods, challenges remain. The integration of new technologies requires manufacturers to update or replace existing machinery, which can be a costly and time-consuming endeavor. Baumann highlighted this as a significant hurdle, explaining, "The packaging industry has existing machines which are all designed for glue materials. Some kind of redesign is probably necessary, and this is our biggest challenge." However, Fraunhofer's Volker Franke suggested that existing machines could be modified by incorporating laser modules, and he believes that the automation potential of the PAPURE technology can help increase production speed.
Another obstacle is the limitation of these technologies on certain paper types. Baumann confirmed that not all paper materials can be bonded with the current methods, but discussions are underway with paper manufacturers to develop bondable raw materials. Furthermore, the PAPURE project has yet to adapt its laser sealing for food-grade packaging, which often requires special coatings that can interfere with the process.
Addressing the challenge of food-grade packaging, Henkel has developed a cold seal solution for barrier-coated paper. Launched in February, this innovation is both recyclable and suitable for food products. Barrier-coated paper is difficult to bond, and heat-sensitive foods like ice cream or chocolate cannot withstand heat-based sealing methods. Henkel's cold seal solution uses pressure to bond the coated paper against itself, providing a viable alternative to traditional adhesives in sensitive applications.
