While paper and cardboard are among the most recycled materials in Europe, the adhesives, labels, and coatings used in packaging often complicate the recycling process. These materials, frequently referred to as “stickies,” can damage machinery or result in lower-quality recycled paper, sometimes leading to entire batches being rejected.
To address this, European regulations are becoming increasingly stringent. New packaging waste rules (PPWR) mandate that all packaging must be at least 70% recyclable by 2030, with that requirement rising to 80% by 2038. In response, several German companies are pioneering methods to seal paper packaging without the need for traditional adhesives.
The Fraunhofer research organization launched the PAPURE project in 2023 to develop a laser-based heating process for sealing paper. Fabian Kayatz, a research group leader at Fraunhofer, noted that the technology is unique because it avoids foreign materials, adding, “If we are optimistic, we will have the first solution out in two years.” Similarly, the engineering firm Hermann Ultraschall has acquired a patent for an ultrasonic sealing process that functions like a weld. Michael Baumann, the company's head of business development for packaging, stated that they are currently in discussions with major market players to bring the technology to mass production.
Transitioning to these methods presents significant hurdles. Existing manufacturing lines are designed for glue-based processes, meaning companies may face costly machinery modifications or replacements. Furthermore, these new sealing techniques do not currently work on all paper types, and production speeds remain slower than traditional methods.
Other companies are focusing on improving the recyclability of the adhesives themselves. Henkel has introduced a cold-seal solution for barrier-coated paper, which is suitable for food products that cannot withstand heat. The company has also developed heat-seal solutions that have allowed brands like Regina to transition from plastic to paper packaging for hygiene products.
Experts suggest that while these innovations are a positive step, broader systemic issues remain. Ambarish Mitra, co-founder of the waste analytics platform Greyparrot, noted that contamination and poor collection methods often prevent paper from being recycled before it even reaches a facility. Jamie Stone of PA Consulting added that the true sustainability impact will be realized as these technologies mature to handle complex packaging at the speed and cost of current plastic lines.
Source: BBC News
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