Schubert Group Expert: Paper Cannot Replace Plastic in every Context

Which trends can be identified regarding the packaging materials used in the confectionery industry, such as less plastic and more paper?

Since the sustainability debate began, there has been a clear trend away from plastic and towards paper. Around 80 percent of our customers at least want to be able to process paper film. From our side, rapid changes are possible. So far, however, the fiber-based tubular bag has not really caught on.

What are the reasons for this?

Firstly, the cost of paper and secondly, the lack of a barrier. In order to create sealability and a decent barrier for protection against external influences as well as a moisture and grease barrier, the paper has to be combined with plastic, and this is detrimental to its recyclability.

Is it possible to use paper completely without plastic?

Not yet, but we support the trend to use as little plastic as possible, but only if it really is the more sustainable solution. We urge our customers to opt for dispersion-coated paper with as little plastic as possible rather than laminated versions. Paper is an ideal substitute for plastic in multipacks. Paper can also be a good solution for some products and packaging that to not require high barriers.

For which products can paper already be used?

Paper makes sense for chocolates without nuts, chocolate-coated products such as marzipan in chocolate or, in some cases, muesli bars.

What options are there for products that require higher barriers?

Mono-material is still the most sustainable solution for these, and the trend towards increased use is continuing. By sealing the film lengthwise with ultrasound and crosswise with our transverse sealing unit, we can process the film particularly gently without sacrificing performance. On the other hand, multi-layer films are still used for packaging that requires high barriers and therefore high impermeability (best before date). However, customers are increasingly moving away from multilayer processes towards mono-materials. There are already some products that have a high barrier.

Are there materials that are now only used by producers in a few cases or not at all?

PVdC is clearly a material that is hardly used any more, especially in Europe. It is a good barrier plastic, but it interferes with the recycling process and can be harmful to health when incinerated. Composites made from different plastics are also becoming less and less common. As the plastics cannot be separated from each other, they cannot be recycled, so the only option to deal with them is incineration. There is also a trend away from metallization.

You mentioned the trend away from plastic towards a greater use of paper. Is sustainability the key factor for this?

Most of our orders and projects have to do with sustainability. The companies want it, especially the corporations, the SMEs are a bit behind. But they are all concerned with it. The trend is moving away from plastic, but we can't simply replace all plastic packaging with fiber-based solutions. Customers are often unaware of this and we have to explain it to them first. Firstly, there are not enough trees to implement this, because all paper food packaging is made from virgin fibers, there is no recycled material in them. And secondly, the most important function of packaging is the barrier, and paper and cardboard can't do that. But regarding this, too, the market is moving very quickly.

So a combination of paper and plastic is still required?

Yes, and that is also the reason why paper and cardboard packaging is only very slowly replacing plastic packaging. On top of that there are the problems with the cost-effectiveness of pure paper packaging.

The Schubert Group is based in Crailsheim and has subsidiaries in the USA, the UK, and China, as well as in the IT, precision parts and packaging service sectors. Founded in 1966, the company has around 1,700 employees and produces packaging machines for the food, confectionery, beverage, pharmaceutical and cosmetics industries, as well as technical articles, and is considered the global market leader in top-loading packaging machines.

The Schubert Group will be represented at Fachpack 2024.