Coating and Laminating Sustainable Lamination
more suitable for the paper recycling stream, contributing positively to circularity eff orts in paper packaging.
The regulatory landscape in Europe is continuously changing. New legislation, such as the Packaging and Packaging Waste Regulation (PPWR), is prompting converters to reassess their materials, but specifi c requirements for adhesives remain undefi ned. For now, many in the industry reference voluntary guidelines from European associations like RecyClass and CEFLEX. These bodies provide frameworks on how adhesives should behave in a recyclable structure, but none have yet been adopted as formal legislative standards linked to PPWR.
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n the evolving landscape of packaging, lamination adhesives are at the heart of an industry-wide transformation. With legislative pressure, consumer demands and brand commitments uniting, converters are seeking more sustainable solutions without sacrifi cing effi ciency, performance or cost-eff ectiveness. This shift is particularly visible across the European market, where lamination processes are being scrutinised for their environmental impact, and innovation is rising to meet the challenge. The push for sustainable lamination can be split into two interconnected trends. Firstly, there is a clear demand for improving the lamination process itself by reducing energy consumption, lowering CO2 emissions, and eliminating volatile organic compounds (VOCs) from adhesives. Secondly, converters and brands are looking for adhesives that support packaging recyclability and compostability. Together, these trends are reshaping how lamination technologies are developed and implemented.
The most prominent development on the process side is the transition from solvent- based adhesives towards solvent-free and, in some cases, water-based systems. Solvent-free lamination brings several immediate benefi ts. These adhesives do not contain VOCs, reducing direct emissions from both the product and the process. Additionally, because there’s no solvent to evaporate, the drying phase can be eliminated, cutting out the need for ovens and drastically lowering energy usage during production. Despite some variability in adoption, the solvent-free adhesive route is rapidly becoming the industry’s preferred path, not only because of its sustainability credentials, but also due to its advantages in cost, process simplicity and investment. Compared to water-based systems, solvent-free technology generally off ers a more attractive value proposition. It’s cheaper to run, doesn’t require extensive drying equipment, and reduces the total cost of production. There is also growing demand for adhesives that are compatible with recyclable mono- material packaging structures and with compostable packaging structures. Solvent-free adhesives generally require lower dry coating weight compared to solvent-based technology. A lower applied adhesive weight reduces the amount of dissimilar material in the mono-material packaging structure and helps improve its performance in the recycling process. In parallel, water-based adhesives are being evaluated for paper laminations, particularly as the paper recycling stream is diff erent to the mechanical recycling of the plastics stream. Their chemical nature and ease of resolubilisation in the repulping process, therefore, make them
In response to this, Sun Chemical has developed specifi c adhesive technologies that address both process effi ciency, goods protection and end-of-life performance. For example, its PASLIM barrier adhesives, a patented, solvent- free technology designed not only to deliver the benefi ts and performance of conventional solvent-free technology, but also to enhance gas barrier performance in mono-material structures. The industry is exploring how adhesives can be designed to off er multiple functions within a single product, materials usage and fi nal capabilities, such as barrier performance or fast curing, directly into the adhesive layer. Converters can simplify their lamination stacks, reduce materials usage and streamline production steps. This integrated approach contributes to both material effi ciency and cost competitiveness. The long-term vision for sustainable lamination includes not only improving existing adhesives but also reimagining the structure of laminated packaging itself. Sun Chemical tries to anticipate how the industry will transform; this could be the customers’ needs, market shifts or regulatory changes. The goal is to pack more functionality into fewer layers and fewer application steps, reducing materials by lightweighting, boosting recyclability and increasing speed-to-market. This means developing multi-functional adhesives that off er high bond strength, barrier properties and environmental compatibility all in one. By staying close to customers, anticipating regulatory shifts and driving innovation in formulation and application, Sun Chemical is staying ahead of the curve by making steady progress towards a more sustainable lamination landscape and allowing its customers to continue growing and developing.
10
November 2025
www.convertermag.com
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