The biennial conference at the SKZ-Modellfabrik Würzburg on 1 and 2 July 2025 offered a comprehensive insight into current developments and trends in barrier laminates. The focus was on new material solutions and innovative manufacturing processes for monomaterials. In addition, the performance of modern films was impressively demonstrated and precise measurement methods for permeation measurement were presented.
PPWR reshapes responsibilities
Dr Thomas Gröner (TG Pack Solutions) opened the conference with an overview of how the Packaging and Packaging Waste Regulation (PPWR) reshapes responsibilities across the supply chain. With recyclability mandatory from 2030, multi-material structures pose major issues. Manufacturers must now rethink packaging design with a focus on mono-materials, separation capability and circular economy compliance.
Florian Reiter (Borealis) presented advances in machine-direction oriented (MDO) polyolefin films. Improved process control and material selection significantly boost oxygen barrier properties and sealing performance, offering real potential for recyclable, high-efficiency films.
Hendrik Steen (Windmöller & Hölscher) discussed retrofitting MDO units to existing PE blown film lines to enhance barrier film production. The upgrade can reduce edge trim by up to 50%, cut material waste and open new market opportunities with sustainable MDO-PE film solutions.
Dr Benedikt Hauer (Fraunhofer IPM) demonstrated inline measurement techniques for ultra-thin oxide barrier layers using infrared reflection spectroscopy. His approach enables real-time quality control in industrial roll-to-roll processes, even under vacuum conditions.
Ultra-precise coating with reduced material losses
Norbert Runn (Polytype Converting) highlighted the PGS pressurised doctor blade system for ultra-precise coating with reduced material losses. In partnership with BASF and Mitsui Chemicals, he presented solutions for multi-layer coating on both film and paper substrates, including solvent-free lamination.
Marco Schmidt (Bobst Meerbusch) introduced the oneBARRIER concept for recyclable, high-barrier paper packaging. Combining metallisation (AlOx, AluBond) with heat-seal coatings, this solution retains barrier performance even after folding, achieving recyclability of up to 95% based on CEPI and Aticelca standards.
Thomas Lunz (Mondi) and Marissa Schwinn (traceless materials) presented paper-based barrier materials combining functionality and recyclability. Traceless develops home-compostable biopolymers from agricultural residues, while Mondi contributes expertise in coatings and metallisation to create sustainable, recyclable packaging.
Dr Phil Rosenow (Fraunhofer IVV) argued for function-based life cycle assessments (LCA), showing that reducing packaging material alone is not sustainable. Using minced meat as a case study, he showed how optimised barrier design can extend shelf life and reduce climate impact by preventing food waste.
Natural oxygen-absorbing cultures
Andreas Dietrich (Weber Food Technology) introduced natural oxygen-absorbing cultures such as Bactoferm Rubis, which extend shelf life and stabilise colour in mono-PET packaging for sausage products—enabling additive-free “clean label” solutions.
Dr Ferdinand Somorowsky (Fraunhofer ISC) presented fibre-based stand-up pouches made from over 85% bio-based materials. Using bioORMOCER hybrid polymers, these pouches achieve good oxygen and water vapour barriers and are recyclable and biodegradable.
Dr Philipp Okle (Amcor Flexibles) highlighted the benefits of SiOx coatings for PP/PE-based barrier packaging. Compared to AlOx and aluminium, SiOx offers better clarity, lower defect rates and a carbon footprint reduction of up to 60%, supporting PPWR goals.
Dr Ulrike Helmstedt (Leibnitz Institute for Surface Modification) explored UV-based processes for applying ceramic barrier layers at ambient temperature and pressure. These approaches allow cost-efficient coatings of sensitive substrates without vacuum systems and enable VOC-free formulations.
Permeation testing to replace epoxy bonding
Christoph Zerwas (AMETEK Mocon) introduced a new clamping system for permeation testing that replaces epoxy bonding. This method cuts preparation time by up to 90%, reduces scatter, and improves repeatability, making measurement more efficient and operator-friendly.
Alexander Tovar (Inficon) emphasised that leak detection is essential for meaningful permeation measurement. He introduced the pressure-rise test as a non-destructive, reproducible method, supported by semi-automated inline systems for reliable quality control in production.
Dr Kristina Eißenberger (Albstadt-Sigmaringen University) closed the technical sessions with recyclable multilayer films featuring a metallised protein-based barrier layer. The coating can be enzymatically separated, enabling high-quality recyclates and moving closer to truly circular, bio-based packaging systems.
Conclusion: Performance over ideology
Karsten Schröder concluded the conference with a concise summary of all the presentations. It is time to think about packaging independently of the material. Depending on the application for which a packaging material is better suited, this may be paper, but for another application it may be (laminated) film or possibly even a biomaterial. It is important to use the most suitable material in each case and not to think ideologically in one direction. This is what the PPWR demands, and the big slogan is “Minimise”! In its compactness, the conference showed that minimal packaging is not a trend, but the future. Innovation, dialogue and collaboration are driving sustainable solutions and shaping the packaging world of tomorrow.