Switching to paper-based packaging – your questions answered

Have you been thinking about making a packaging switch? 
Are you eager to go plastic-free or away from multi-layer foils? 
Are consumers telling you that it’s time to bring your packaging concepts to life in a sustainable way?

We believe that the future of flexible packaging is paper based. But we know that making the switch is no simple matter. That’s why we’ve put together these barrier papers FAQs as a useful guide to taking the next step…

What are the main challenges for switching to barrier papers in terms of functionality? And how do you overcome them?

First, product protection – it’s crucial that the protection of the product is not compromised compared to the current packaging. An example of this is ensuring a certain best-before date. A reliable and secure supply chain is also important for retailers.

Second, the barrier papers should ideally run on existing packaging lines – so as to avoid major investments in new machine components or entire systems. In such cases, optimisations are necessary. At Sappi, we work closely with packaging machine manufacturers to carry out tests which make it possible to switch from conventional materials to new, more sustainable materials.

Third and most important is to use a material that can be recycled in the paper waste stream, rather than ending up as ordinary waste (as is the case with much of today's packaging). The right choice of barrier paper will protect your products, run on readily adapted machinery and be recyclable in the paper waste stream.

For which dry products are barrier papers suitable and not suitable? And where might normal paper or glassine be sufficient?

The term "dry products" includes products such as cereals, coffee, dried fruit, flour or ready-made soups. Each of these products has specific properties and therefore requires an individual barrier to ensure effective protection – especially in the case of food to ensure the best-before date.

"Normal" paper does not offer a barrier and is therefore fundamentally unsuitable. Glassine, a high-density paper, is largely grease-proof, but offers no protection against moisture. For example, it is suitable for packaging butter, but is less suitable for other applications. In addition, neither normal paper nor glassine can be sealed.

Barrier papers, on the other hand, offer a combination of optimally adapted protection and functionality that make them ideal for many dry products.

How do you test the functionality of barrier papers?

At Sappi we use special measuring instruments to thoroughly test our barrier papers. We test the permeation – the permeability of oxygen, water vapour or mineral oil (MOSH/MOAH) – to ensure the necessary protection in each case. For papers that also need to be heat-sealable, we check the achievable seam strength. All these measured values are then shown in the respective data sheets.

How flexible are barrier papers in terms of their runnability on existing packaging lines or their different thicknesses?

Our Sappi barrier papers can be processed on existing packaging lines, depending on the type of packaging you want. A small, individually packaged bar has different requirements than a large bag containing many small products. The processability of the packaging material into the finished packaging also depends on the packaging machine, which is why we work closely with the machine manufacturer.

In most cases, the technicians of the brand manufacturers manage to convert existing packaging lines to paper-based packaging materials – especially barrier papers – on their own. A changeover is often necessary because the plastic films and laminates used today are very thin, flexible, robust and tear-resistant. Paper, on the other hand, is less tear-resistant and requires more sensitivity in the packaging process.

What role do legal requirements play in this area?

Regulations and requirements are central guidelines for us in the development of paper-based solutions, and at Sappi we strictly adhere to them. In the field of food packaging, for example, our barrier papers must always be suitable for direct food contact. In addition, all materials entering our production facilities must be approved for direct food contact. We have to prove this suitability and declare it accordingly. That’s why we work with external test laboratories that check food safety and issue us with the necessary certificates.

When new legal requirements, such as those to increase the recyclability of packaging, come into force, we naturally comply with them. Basically, our goal at Sappi is to ensure that packaging made from our papers is recyclable at the end of its life cycle.

How do you ensure the recyclability of your barrier papers?

At Sappi, we have established, internal control mechanisms. Our papers are first tested in an internal, non-accredited laboratory following specified measurement methods according to CEPI or the PPWR (Packaging and Packaging Waste Regulation). This allows us to determine at an early stage whether the papers meet the specifications and to make adjustments if necessary. Our papers are then sent to accredited, external test laboratories for testing, who issue us with the corresponding certificates. Our customers receive these certificates as reliable proof of the recyclability of the barrier papers.

How do you approach the issue of sustainability in raw materials?

Sappi has implemented transparent practices by using internationally recognised, independently verified certification systems including the Forest Stewardship Council™ (FSC™ N003159), the Programme for the Endorsement of Forest Certification (PEFC/01-44-43) and the Sustainable Forestry Initiative® (SFI®).

Knowing the origin of woodfibre is essential for responsible sourcing of wood and pulp. All of Sappi’s mills have been FSC Chain of Custody (CoC) certified since 2008. Our 400,000 hectares of owned and leased plantations in South Africa are both FSC and PEFC certified. We use the raw materials from these forests exclusively for local production. This means that no wood or other raw materials go from South Africa to Europe. At our European mills, we source the wood required for the production of pulp from a radius of approximately 150km of the respective mill.

When a customer orders certified material, the delivery and sales documents will always carry the respective claim and our certification number(s). And thus each delivery is verified to originate from controlled, non-controversial sources per FSC and PEFC standards.

What about price? Are barrier papers more expensive?

It depends on the comparative material. The materials used today range from mono-plastic films to multi-layer laminates that are not comparable in price. At first glance, barrier papers may seem more expensive. However, in several countries there are incentives, or premiums, for materials that are easier to recycle – and this should always be included in the final cost analysis. In addition, anyone who places packaging on the market must pay a recycling levy, the rate of which which depends heavily on the raw material used. Paper-based mono material like barrier paper solutions offer an advantage in this context.

What makes Sappi barrier papers different?

As a pioneer in this field, Sappi started producing barrier papers more than 10 years ago. That means we have built up experience and expertise that few in the market can match. Thanks to pioneering dispersion technology, we produce our barrier papers in such a way that they can be easily recycled in the paper waste stream. We are also the manufacturer offering the largest range of barrier papers – and are continuously expanding our already broad portfolio with new products. Instead of offering oversized standard products, we develop tailor-made solutions that are precisely tailored to the barrier requirements of our customers. This allows us to react quickly and flexibly to individual needs.