Coating and Laminating
cent and 80.9 per cent respectively, and the rate for corrugated cardboard boxes is a remarkable 96.5 per cent. In Europe, recycling rates for paper products sit at around 83.2 per cent, compared with 41 per cent for plastic .
THE PAPER CHALLENGE
Yet despite the problems with recycling just described, plastic packaging is still with us, because it continues to perform vital packaging functions. It’s durable, lightweight, available in rigid, semi-rigid and fl exible formats, resists moisture and contaminants, preserves freshness and extends shelf life, and is low-cost to produce. Replicating these benefi ts poses a challenge to paper. Take plastic’s protective qualities, for example, its excellent barrier properties and puncture resistance, especially for food and beverage packaging. These are challenging to replicate in a fi bre-based package, because in its natural state, paper is porous, breaks down easily when exposed to moisture and lacks the robustness of plastic.
CHEMISTRY COMES TO THE RESCUE While paper-based packaging isn’t perfect for all applications, in recent years, thanks to advances in chemistry, it now provides a genuine alternative for the protection and preservation of a huge range of perishable goods, without compromising paper’s natural advantages of recyclability and compostability.
PULP TO PRODUCT
To appreciate the critical role chemistry plays in making paperization possible, consider the diff erence it makes throughout the production process, from pulp to paper. Because creating paper-based packaging for specifi c needs – especially when it comes to retaining the integrity of fragile or perishable goods – doesn’t begin with simply choosing the right fi bre-based product for the job. It starts all the way back at the start of the pulping process — with creating the right fi bre-based packaging materials to begin with. Paying attention, at the outset, to raw material processing, sets a vital and strong foundation for the quality and functionality of the fi nal packaging products.
An early important decision is to select the correct cleaning and bleaching agents, solutions that aid the removal of impurities and enhance fi bre brightness. Thanks to recent developments, a variety of more sustainable solutions are available that reduce reliance on chlorine-based bleaches. Likewise with wet and dry strength resins, formulated to reinforce paper fi bres both during pulping and in subsequent sheet formation. These products help improve tensile
and tear resistance while ensuring lower breakage rates.
At the paper machine, using retention aids improves runnability by reducing sheet breaks, increasing the retention of fi bres and fi llers and thus producing cleaner back water. Surfactants help in detaching ink particles and fl oating them. Passivation chemistry counters the tendency for coatings and adhesives to be only partially removed during the deinking process. Treating pulp fi bres in a way that minimises waste and maximises yield contributes to sustainability.
BARRIERS SHOULDN’T BE A BARRIER As noted earlier, eff ective barrier coatings are critical for improving the performance of paper- based packaging, providing moisture protection to shield products from humidity and water; resistance to grease and oil for food packaging; and extended shelf life. Today, a new generation of recyclable and compostable barrier coatings are available to help brands transition to more sustainable, paper-based solutions. These meet food safety standards and ensure compliance with regulatory requirements. And, they often reduce or eliminate the need for unsustainable options like protective plastic fi lm or lamination, helping companies transition to more recyclable and compostable alternatives.
Coatings also contribute to improving the printability of paper substrates — particularly important for branding, labelling and information delivery on packaging materials, ensuring that design and messaging remain vibrant and clear.
BACK TO THE BEGINNING
At the end-of-use stage, new chemistries support repulping and recycling. Barrier coatings and functional additives that are easily separable
from fi bres enable effi cient recycling processes, simplifying the conversion of used packaging into high-quality recycled material and aligning with the industry’s growing emphasis on closed-loop systems. In doing so, they help manufacturers and brand owners meet stringent sustainability objectives, including reducing landfi ll waste and dependence on virgin materials.
CLOSING THE LOOP: CIRCULAR PRODUCTION, NOT CIRCULAR THINKING As paperization gathers pace, it will become increasingly important to choose chemistry that enhances sustainability without compromising functionality. This means choosing the right partner too, one that understands the specifi c challenges at each step of the packaging value chain and can deliver tailored solutions. Chemistry from Archroma Packaging Technologies supports every stage of the manufacturing process, acting as the backbone of an increasingly sustainable and effi cient packaging ecosystem.
FORMULATING FOR THE FUTURE For Archroma Packaging Technologies, the story doesn’t just begin and end with paper. The real focus of the business lies in solving customer problems to make all packaging – regardless of substrate – both functional and designed with sustainability in mind.
As CEO, Sameer Singla, says: “Chemistry plays an imperative role in packaging. The substrate alone – be it traditional materials like paper, or newer bio-based alternatives coming to market such as banana leaves or rice husk – doesn’t create a functional package. Chemistry is the critical enabler, and it must be sustainable. As a company, we are committed to fi nding the right solution for each and every customer.”
www.convertermag.com
May/June 2026
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