Right now, companies across markets urgently need more sustainable packaging solutions—to adapt to shifting consumer preferences and comply with increasingly strict regulations like the EU’s PPWR. But successful responses to these industry-changing trends require businesses to embrace holistic approaches that consider the entire value chain. And success also relies on creative concepts that reimagine long-established packaging designs, materials and processes.

Forward-facing collaboration between organizations in the packaging ecosystem can play a key role in unlocking the necessary sustainable innovations. Experts from Windmöller & Hölscher (W&H) and Henkel worked together to develop a paper-based alternative to plastic packaging. The result? An inline coating approach that transforms paper into fully recyclable packaging while delivering the performance needed for a wide range of applications.

W&H is a world-leading provider of machinery and systems for the production of flexible packaging.  It has a long-standing relationship with Henkel, which provides advanced and sustainable adhesives, sealants and functional coatings for almost every industry. As the latest step in their long partnership, the two companies worked side by side to design and implement a breakthrough inline-coating solution that addresses key challenges for today’s packaging sector.

These challenges reflect the demanding requirements of modern packaging. It must protect products from water moisture and grease. While enabling cost-efficient, high-speed processing and exceptional heat-sealing. Until recently, plastic-based and laminated packaging has been the industry standard because paper could not meet these functional requirements. But now, W&H and Henkel have created an alternative solution.

This packaging innovation combines Henkel’s water‑based AQUENCE BC 5100 RE (formerly known as AQUENCE EPIX BC 5100) coating with W&H’s advanced printing technology. Functional layers are applied in a single inline printing step. This eliminates the need for separate offline coating steps and unlocks exciting new sustainability benefits for businesses across packaging value chain.

Henkel’s coating gives paper the necessary mechanical robustness, heat‑sealability and protective barriers for modern food and non-food packaging applications. It is suitable for high-speed applications involving various types of paper. The cyclos‑HTP certification confirms that the resulting paper packaging is fully compatible with established recycling systems.

By combining W&H’s printing technology with the water-based technology behind Henkel’s coatings, this joint project turn paper into fully recyclable and high-performance packaging. This makes it possible for companies and brands to replace plastic packaging with paper-based alternatives that meet shifting consumer preferences and comply with relevant regulations. By eliminating the offline coating step, the new approach further contributes to sustainability by saving energy and reducing the associated CO2 emissions.

Employees at W&H and Henkel share a deep sense of pride in this future-facing and environmentally compatible breakthrough. Now, the partners are excited to maximize the positive contribution of their work by bringing this scalable and high-throughput solution to the market. They are also continuing to exchange ideas and explore further opportunities to advance circularity, sustainability and regulatory compliance in the global packaging industry.