HYBRID PACKAGING MATERIALS
Michelman image: Michelman Introduces Nuvita® Life 4002 & Nuvita® Life 4605: Bio-Based Barrier Coatings for Paper Packaging Applications
Fermtech CEO Andy Clayton
The answer, however, cannot be
determined by looking at the product in isolation. A shorter shelf life can affect retailer inventory practices, distribution models and supply-chain complexity, potentially creating operational challenges further down the value chain. This is where the promise of mono-
material packaging becomes particularly interesting. Rather than relying on a
collection of different materials,
developers are looking at ways of building the necessary functionality into a simpler structure, whether
through coatings
applied directly to paper or functional layers within mono-material films. “Mono-material packaging is becoming
increasingly important due to regulatory developments and growing demand for improved recyclability,” Anna says. The objective is straightforward: maximise the proportion of packaging that can enter a single recycling stream without sacrificing the performance that made the original multi-layer structure necessary in the first place. Starch-based coatings are one route
being explored. Cargill’s modified starch technologies are designed to provide oil and grease resistance using standard
34 • KENNEDY’S CONFECTION • JULY 2026
paper-coating equipment, potentially allowing functional performance
be added without introducing another substantial material layer. Hydrocolloids, meanwhile, are opening
another avenue. Pectin and carrageenan are attracting attention for oxygen barrier applications, while bio-based waxes are being considered where moisture resistance is the primary requirement. Anna cautions that the industry is not
yet at the point where these emerging materials can universally replace conventional plastic-based barriers. “Most emerging solutions still require
further optimization before they can consistently match the full performance range of conventional plastic-based structures across all confectionery applications,” she says. That caveat is important because
packaging performance is not determined by barrier properties alone. Sealing and machinability can be just as critical, particularly in an industry where products are packed at high speeds and even small changes to packaging behaviour can affect line efficiency. Sealing, in particular, remains one of the more difficult hurdles for bio-based structures. A material can
to
deliver the required oxygen, grease or moisture barrier but still fall short when it needs to form a reliable heat seal. This is creating an important role for
hybrid packaging. Rather than attempting to remove every synthetic component, packaging developers can retain a thin synthetic layer where it provides a specific function – such as reliable sealing – while using bio-based materials elsewhere in the structure to provide barrier performance. “In these structures, bio-based materials may provide
sealing and packaging line
barrier
performance in the inner layers while a thin synthetic layer is retained to ensure reliable
efficiency,” says Anna. The approach reflects a broader shift in
the way packaging sustainability is being considered. Rather than treating material reduction as an end in itself, the objective is increasingly to optimise the entire structure around its performance. For manufacturers considering a
move away from conventional multilayer packaging, Cargill identifies four considerations: product protection, sealing and machinability, regulatory compliance and future readiness, and
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