The EU Packaging Regulation (PPWR) also imposes new requirements on manufacturers of industrially produced baked goods for the food retail sector. The focus is on recyclability: established polyamide (PA) composite structures must be reviewed and, where necessary, replaced with more recyclable designs. The film manufacturer SÜDPACK has consistently developed its portfolio and already offers solutions for the sector that combine product protection, machine performance and cost-effectiveness.
“Those who only react once new regulations come into force immediately lose valuable time,” is SÜDPACK’s credo. To ensure that new packaging solutions work in practice and that the PPWR requirements regarding recyclability are met by 2030, bakery product manufacturers should explore alternative packaging solutions at an early stage. After all, the transition requires lead time. Material selection, sampling, technical validation and cost-effectiveness assessments cannot be carried out at short notice.
What is – and what will be – important for the bakery sector?
Above all, the stricter requirements for recyclability are among the most far-reaching provisions of the PPWR. Traditional multilayer composite solutions with a high polyamide content are particularly problematic. However, it is precisely these PA composites that are currently the preferred packaging materials for industrially produced bakery products. They offer the perfect combination of mechanical protection for sharp-edged crusts, good barrier properties for a long shelf life, reliable processing on packaging machines and, last but not least, economic benefits. However, due to their composite structure with a high PA content, they do not sufficiently meet future recyclability requirements. This applies, amongst other things, to lid films with traditional carrier systems, which are now established in many applications. Similarly, numerous tubular pouch applications are under scrutiny.
Alternative packaging solutions – designed for recycling
In response to the PPWR, SÜDPACK is working intensively on new packaging concepts that are both product- and recycling-friendly. One concrete innovative approach is the further development of material combinations so that they remain functional whilst better fitting into future circular systems.
In parallel, the portfolio of PP- and PE-based packaging systems has expanded further. These monomaterial solutions can already be fed into existing recycling streams in many European countries. However, these materials present greater challenges in terms of mechanical properties and processing. But solutions exist here too: through collaboration with numerous packaging machinery manufacturers, the machinery and film have been optimally matched, and the packaging concept has been successfully introduced to customers.
Practical example of tubular pouch applications
One example is the CarbonLite product family. The PP- and PE-based films can be processed on horizontal and vertical form-fill-seal machines to produce sturdy flow packs for baguettes, bread rolls, rustic loaves or pastries. Barrier and sealing properties help protect against moisture and oxygen; the puncture resistance is designed to withstand mechanical stress from crusts, edges or grains.
Thanks to SÜDPACK’s expertise in co-extrusion, the materials are constantly being further developed. For example, for PE-based horizontal flow-wrap applications – a potential use for packaging baguettes – a further reduction in thickness of 10 per cent in total has been achieved compared with the previous film, whilst maintaining the same level of stability.
How can the transition be made as smoothly as possible?
Against the backdrop of all these factors, the recommended course of action remains: bakery product manufacturers should, if possible, start exploring alternative packaging solutions today and rely on expert solution providers and factual evidence. Those who gain experience with new materials and structures now, who thoroughly validate new packaging concepts and examine them rigorously from both a technical and economic perspective, can take on a pioneering role in the market and secure valuable competitive advantages. Film specialists such as SÜDPACK offer an experienced team of developers and application engineers to provide customers with the best possible support right from the start when introducing new packaging concepts, and to underpin decisions with well-founded data.