German companies pioneer adhesive-free paper packaging sealing methods

German companies are developing innovative paper packaging sealing technologies to eliminate non-recyclable adhesives and improve recycling outcomes. Research organisation Fraunhofer, engineering firm Hermann Ultraschall, and chemical company Henkel are developing adhesive-free, specialised sealing solutions to meet tightening European regulations. Non-recyclable adhesives can damage recycling machinery and reduce the quality of recycled paper batches, prompting the push for cleaner packaging alternatives.

BBC reported that non-recyclable adhesives present significant challenges to current recycling processes, despite paper being one of Europe's most recycled materials with a 74% recycling rate in 2024. In response, Fraunhofer established the PAPURE project in 2023 to develop a laser-based heating process to seal paper without adhesives. Fraunhofer group leader Fabian Kayatz stated that the team hopes to bring the technology to market within two years following interest at the Interpack trade show.

Simultaneously, Hermann Ultraschall acquired rights to develop a patented ultrasonic paper sealing technology that operates similarly to welding. Hermann Ultraschall head of business development packaging Michael Baumann confirmed the company is in discussions with major industry players to bring the process into mass production. However, updating existing production machinery designed for traditional glue materials remains a primary challenge for widespread adoption.

Henkel has introduced complementary solutions, including a cold seal process for barrier-coated paper suitable for food products like chocolate and ice cream. Henkel market strategy manager Dr Arianna Savini explained that paper offers a clear path toward improving packaging recyclability within established systems. While experts note that machinery costs, production speeds, and waste sorting methods remain hurdles, these advances support compliance with the Europe-wide packaging and packaging waste regulation mandating 70% recyclable packaging by 2030.