Heidelberg is moving ahead in the coveted market for fiber-based flexible packaging. In partnership with American chemist Solenis, the German manufacturer is proposing the integration of barrier coating into its Boardmaster rotary flexo line, to be launched in 2023. This technical development will be unveiled at the Fachpack 2025 trade show in Nuremberg, Germany, from September 23 to 25.
Papierisation, a long-term packaging trend
This new process targets paper packaging producers looking for an industrializable alternative to multilayer plastic films. According to a study conducted by the German DHBW Heilbronn University, with the support of Heidelberg, this segment, also known as "paperization", is set to grow by 4.5% a year between now and 2030.
And for Professor Carsten Kortum, in charge of the investigation, "this is not a short-term trend, but a profound change, driven by new regulatory requirements, heightened environmental awareness and changing consumer behavior, combined with technological innovations."
An induction model for selective in-line barriers
The technological response proposed by the printing press manufacturer consists in integrating a coating module within the Boardmaster. The special feature of this module is its ability to apply barrier coatings only to the areas required.
The fully in-line process combines printing and application of the barrier solution in a single pass, reducing production steps, costs and waste.
The varnish used was developed by Solenis, a North American supplier of chemical solutions for water and paper treatment.
The solution is aimed in particular at the food, cosmetics and non-food sectors, where protection against liquids, oils or water vapors is required. Until now, these barrier functions have required multi-layer laminates, which are often difficult to recycle. With this device, substrate recyclability is maintained.
"Economically viable innovations are essential if we are to replace plastic packaging with recyclable or compostable paper solutions", says David Schmedding, Group Sales Director.
"By collaborating with Solenis on the development of varnishes and inks, and producing coated paper packaging inline, Heidelberg confirms its role as the driving force behind paperization. In this way, we are acting as a complete solutions provider for the mass production of fiber-based packaging."
Public preview at Fachpack 2025
Visitors to Fachpack will be able to find out more about this process at stand 4A-342, where Heidelberg and Solenis will be presenting samples produced on the Boardmaster equipped with the coating module. Experts from both companies will be on hand to explain the technical parameters of coating.
