Packaging

A new dust-tight sealed 100% paper packaging solution

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Stockholm-based BillerudKorsnäs – a provider of sustainable materials for the packaging industry – and Bosch Packaging Technology, have launched their Sealed Paper Packaging technology, in order to replace conventional packaging for dry foods with a new all-paper and dust-tight sealed solution.

Over the last few years Bosch Packaging Technology and BillerudKorsnäs have been working together to develop a new dust-tight sealed 100% paper packaging solution, produced on Bosch’s vertical form, fill and seal lines (VFFS) and building upon BillerudKorsnäs’s Axello ZAP paper. German-based sugar producer Pfeifen and Langen, with whom the two companies had previously been in talks, was the first to commission a prototype of the complete system. A PME 4001 ZAP machine was reportedly installed, in fact, at its Elsdorf, Germany, facilities, early this year. According to sources, the Sealed Paper Packaging technology allows companies to replace their conventional bags with these new models, able to ensure strength and stability and, at the same time, to reduce their environmental impact while enhancing their customers’ experience.

Ole Paulussen, sales director at BillerudKorsnäs.
Ole Paulussen, sales director at BillerudKorsnäs.

«The secret», as Ole Paulussen, sales director at BillerudKorsnäs, told Paper Industry World, «lies both in the partial inline application of the sealing agent, which allows for tightly sealed paper bags, and the specially developed paper. As a result, throughout the supply chain no dust can enter the surroundings. The product can’t be contaminated once the packaging process has been completed». This is also due to the «unique forming shoulder», providing a «gentle processing of the paper», that the Bosch machine can offer, whereas the Axello ZAP paper, developed by Stockholm based BillerudKorsnäs, has already proven to be more durable and resilient than traditional paper. Last, but not least, it is fully recyclable. «The solution», as sales manager for the VFFS ZAP portfolio at Bosch Packaging Technology Marcus Velezmoro pointed out, «provides optimal performance and cost savings. For example, material costs are significantly reduced compared to film-based bags (average 30-40%), on top of savings in logistics and storage costs. The solution also offers faster return on investment in comparison to mandrel wheel machines (about 40% of investment), which so far were the only option for producing paper bags from the reel in VFFS technology (80%)». BillerudKorsnäs claimed it already estimated a solid total cost of ownership cases: «It clearly points towards lower costs over time», Business Development Director Packaging Paper, Patrik Bosander, stated, «both in terms of financials and environmental footprints. For the latter, we have an independent and third party reviewed report presenting clear environmental benefits of the Sealed Paper Packaging system, compared to conventional plastic packaging for e.g. pasta. In addition, we are convinced that the growing environmental awareness among consumers and their search for natural products and materials, will render brands using this new pack style a higher shelf appeal».

The sales manager for the VFFS ZAP portfolio at Bosch Packaging Technology Marcus Velezmoro.
The sales manager for the VFFS ZAP portfolio at Bosch Packaging Technology Marcus Velezmoro.

As for the technologies requested for implementing this kind of process, Marcus Velezmoro stated that «for the moment it is mandatory to acquire the complete solution, including the Bosch VFFS machine with ZAP sealing module and the Axello®ZAP paper». However, he explained, «being the machine based on a standard semi-continuous VFFS concept, it is easy to adjust to existing production lines».

Based on mono-material fiber, Axello®ZAP paper achieves greater consumer impact while limiting the effect on the environment. Using fully renewable and biodegradable material, from FSC certified sources, this first sealed paper bag truly stands out from competition. Moreover, the unique mechanical properties of the paper provide optimal processing and excellent stability while retaining natural character – from source to recycling. No other paper available on the market can achieve these results.
Based on mono-material fiber, Axello®ZAP paper achieves greater consumer impact while limiting the effect on the environment. Using fully renewable and biodegradable material, from FSC certified sources, this first sealed paper bag truly stands out from competition. Moreover, the unique mechanical properties of the paper provide optimal processing and excellent stability while retaining natural character – from source to recycling. No other paper available on the market can achieve these results.

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