how to turn today’s packaging challenges into competitive advantage with high-performance barrier papers
Herwig Kirchberger
Managing Director of DELSCI and Key Account Lead
Regulatory frameworks such as SUPD and PPWR, and eco-modulated EPR fees for less sustainable, hard-to-recycle packaging solutions, are creating pressure to improve packaging circularity while maintaining product performance and operational efficiency.
Fiber-based barrier packaging is an ideal solution, but for companies the key question is how this transition can be successfully implemented.
Navigating these trade-offs requires both technical and regulatory expertise at the same time. Leveraging decades of paper and barrier technology know-how and the advanced R&D capabilities of delfort’s DELSCI team, we support and enable customers develop high-performing packaging solutions that reduce risk, accelerate innovation, and create a competitive advantage in a rapidly changing market.
Why developing new paper packaging solutions is more complex than ever
Creating effective paper-based packaging requires balancing a range of competing requirements.
Functional barrier papers have to deliver the right level of protection against moisture, oxygen, grease, aromas, or mineral oils while remaining compatible with sorting and recycling streams and existing converting and packaging processes. At the same time, they must meet food-contact regulations, reduce the total environmental input of a product, support brand sustainability goals, and remain commercially viable.
The complexity lies in the fact that each packaged product across food, consumer goods, and industrial packaging applications has specific barrier performance requirements. Depending on the product, protection against moisture, oxygen, grease, mineral oils, or aroma loss must be precisely tailored. A successful packaging solution therefore requires the barrier paper to be carefully matched to the product's characteristics and intended application conditions.
Adapting barrier performance through a new material formulation may not only influence processability and cost but also impact recyclability performance and processability on converting and packaging lines. New coatings typically require repeated production validation, regulatory assessments, and process qualification before commercial implementation.
Balancing performance, recyclability, and compliance with barrier papers
Replacing traditional, non-circular packaging materials with barrier papers is typically not only a simple material swap.
Brands need solutions that deliver among other things:
- Ultimate product protection over the whole transport and shelf live
- High filling line efficiency with reliable sealing performance
- Strong visual appearance and printability
- Full compliance with legislation framework
- Proven recyclability at the final packaging level to support circularity targets and reduce EPR-related costs
Achieving these objectives simultaneously requires a product development process that goes beyond material supply. It requires collaborative innovation, co-creation and extensive and agile testing through rapid prototyping solutions.
This is where delfort's integrated development approach creates value.
© © Chris Guetl
Accelerating paper packaging innovation through DELSCI's R&D expertise
A key advantage for our customers is direct access to the scientific and technical capabilities of DELSCI, our dedicated research and development partner.
With around 300m2 R&D laboratories and pilot lines, DELSCI combines advanced material research with practical application expertise, allowing faster development cycles and enabling our customers to make scientifically based, strategic packaging decisions at an early stage.
Successful packaging development is never about optimizing independent parameters. It is about considering the interactions between all the relevant factors of barrier performance, processability, recyclability, and end-use requirements already at an early product development stage. And finally, it is about industrialization excellence to deliver robust packaging solutions!
This scientific and application-focused approach helps customers reduce uncertainty and accelerate innovation while ensuring final packaging performance.
From concept to commercialization: delfort's stage-gate process for packaging development
Speed is critical in today's packaging industry. Brands need innovative solutions that can be quickly tested, reliably validated, and implemented efficiently.
To support this, we offer a structured but agile innovation process to significantly reduce development risks while shortening time-to-market for customers.
1) Proof-of-concept on laboratory samples
After validating the strategic, technical and commercial fit of a new opportunity, development typically starts with mock-up building, rapid material screening and testing first prototypes on a laboratory scale. New paper-coating combinations can be quickly assessed for technical fit before larger-scale prototyping.
2) Reel-level testing in our rapid prototype center
Promising laboratory samples are transferred to small reel production, allowing realistic assessments of processability on production lines, barrier performance, and convertibility checks. At that level the recycling characteristics of the barrier papers are evaluated the first time using the CEPI Recyclability Test Method, Version 3.
3) Package-level validation in the packaging laboratory
New barrier paper prototypes are comprehensively tested across all parameters under practical application conditions. That includes packaging runnability on HFFS and VFFS lines, sealing performance, and accelerated shelf-life testing.
4) Upscaling and market launch
Before commercialization, qualified barrier paper grades undergo multiple validation iterations under production conditions to ensure repeatable performance, process stability, and scalability.
Why packaging innovation requires collaboration across the packaging value chain
Fiber-based packaging development is a multi-disciplinary field of paper production, material science, process engineering, food science, regulatory affairs and waste management. The expertise required to create a successful packaging solution is distributed across the value chain.
The success of a packaging concept is not determined by a single material property, but by how the entire structure performs throughout its lifecycle, from manufacturing to filling, consumer use, and recycling.
For example, a barrier solution that delivers excellent product protection must also run efficiently on converting and packaging lines, support reliable sealing, comply with regulatory requirements, and contribute to the recyclability performance of the final packaging. As evolving regulations and recyclability criteria increasingly favor fiber-based packaging with high paper content, materials must deliver the required functionality while minimizing non-fiber components. This requires close collaboration across the value chain:
- Brand owners define product protection, shelf-life, sustainability, and commercial requirements.
- Paper manufacturers contribute fiber, material and barrier expertise.
- Converters add final barrier and printing layers and ensure efficient processing and packaging line performance.
- Regulatory experts assess compliance with evolving legislation.
- Recyclers provide insights into compatibility with established paper recycling streams.
At delfort, we work closely with customers and partners to understand not only the requirements of the paper itself, but also the impact of material choices on the entire packaging system. This enables us to develop barrier paper solutions that balance product protection, operational efficiency, regulatory compliance, and recyclability.
Turning packaging complexity into competitive advantage
As packaging requirements continue to evolve, success depends on balancing performance, compliance, and recyclability.
- High-performance barrier papers must meet multiple packaging requirements simultaneously.
- Collaboration across the value chain is essential for successful packaging innovation.
- Rapid prototyping and industrial validation accelerate commercialization.
- With deep material expertise and collaborative development, we help customers turn packaging complexity into a competitive advantage.
FAQs
Can barrier papers deliver both high performance and recyclability?
The latest generation of our cutting-edge barrier papers delivers excellent product protection, recyclability, and efficient processability on converting and packaging lines for a variety of applications without compromising on performance. For demanding applications requiring ultra-high barrier properties (MVTR and OTR << 1g/m2.day), barrier papers can be combined with suitable, non-paper materials to provide a circular, high-performance barrier packaging. For these challenging applications we closely collaborate with converting partners and can also offer a total solution for your packaging needs.
What makes paper packaging recyclable?
A paper packaging solution is recyclable when it can be efficiently processed in existing paper recycling mills with conventional process while maintaining high fiber recovery and low residues. Factors such as barrier coatings, adhesives, laminations, and the proportion of fiber and non-fiber components can influence recyclability.
Recyclability requirements and test methods vary by region, with different standards applied in Europe, North America, and Asia. To support global market requirements, delfort’s barrier papers are tested according to recognized industry methods and certification schemes, including CEPI, ASTM, and TÜV protocols.
For instance, the CEPI Recyclability Laboratory Test Method helps evaluate whether packaging structures are compatible with established paper recycling streams and support circular packaging design.
What testing is required when developing paper-based packaging?
Paper-based packaging typically requires barrier, mechanical, recyclability, packaging, converting, transport, and regulatory compliance testing. These tests verify that the packaging protects the product, runs efficiently on packaging lines, meets food-contact and legal requirements, and can be recycled within existing paper waste streams. At delfort, we perform all tests on different maturity levels of the product to ensure commercial readiness, from laboratory screening and prototype development to pilot-scale and industrial production trials.
Herwig Kirchberger
Managing Director of DELSCI and Key Account Lead
A recognized expert in fiber-based packaging innovation, Herwig Kirchberger combines more than 25 years of international experience in R&D, technology commercialization, and business leadership. As Managing Director of DELSCI GmbH, delfort’s R&D partner, and as Key Account lead for global brands at delfort, he specializes in transforming emerging technologies into market-ready, recyclable fiber-based packaging solutions for the food and non-food industry.
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