Packaging Europe Issue 19.6

DRIVING INNOVATION IN PHARMACEUTICAL PACKAGING

OUR TEAM

THE CONTENT TEAM

Tim Sykes Brand Director

Victoria Hattersley Senior Writer

Elisabeth Skoda Editor at Large

Libby Munford Journalist

Fin Slater Digital Content Manager

Emma Liggins Journalist

Frances Butler Journalist

THE PRODUCTION TEAM

Rob Czerwinski Creative Lead

Meg Garratt Multimedia Designer

Syed Hassan Digital Analyst

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Kayleigh Harvey Advertising Coordinator

Shona Clacher Customer Success Executive

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ASI write this editorial, the Packaging Europe team is still buzzing from another successful and inspiring Sustainable Packaging Summit in Amsterdam. We welcomed 700 delegates, 55 sponsors and exhibitors, 100+ partners and influencers, and hopefully provided a space for delegates to gain insights, exchange ideas and together forge paths towards a fully circular packaging industry. As we face uncertain times ahead on the world stage, and the sustainability agenda confronts serious headwinds, it was encouraging to see that the

EDITORIAL

will to create a sustainable future is still strong in the packaging industry. Of course, a lot still needs to be done, and we are looking forward to seeing a lot more progress in 2025.

I’d like to extend special congratulations to all our finalists and winners of the Sustainability Awards 2024, most notably Upfield, a winner both in our Renewable Materials and Overall Winner category for their plastic-free, oil resistant and waterproof wet fibre moulded tub for plant-based spreads. A special mention also to the winner of our Readers’ Award, chosen by Packaging Europe subscribers- the award went to Vytal and its fully digital experience for reusable food and drink containers.

With each new edition of the competition, we are more and more impressed by the quality and diversity of the entries. Take a look inside the pages of this magazine for a more detailed breakdown of all the winners. By the way, submissions for next year’s global Sustainability Awards open on 14th January. Find out more about the application process via the competition website. packagingeurope.com/sustainability-awards

Meanwhile, in this edition of the magazine we have a strong focus on pharmaceutical packaging. Libby Munford explores how pharmaceutical packaging can provide patient safety and convenience and discusses the key areas of development and trends driving the industry forward with Schreiner MediPharm’s Stefan Wiedemann, Takeda Pharmaceutical Company Limited’s Sriman Banerjee and Constantia Flexibles’ Agnieszka van Batavia.

In addition, Emma Liggins takes a deep dive into how serialization, which has been compulsory for pharmaceutical packaging for thirteen years, is helping protect consumers from counterfeit medicine.

Victora Hattersley takes a look at what is on the innovation agenda for the packaging industry for 2025 and asks leading industry experts, including Patrick Poitevin, Willemijn Peeters, Dana Mosora, Pia Skoczinski, Nedim Nisic, Rachael Satchwell and Stefan Hilss what they expect.

Flexible packaging offers many functional benefits but still faces a range of challenges around recyclability. I speak to CEFLEX’s Dana Mosora to hear about the latest developments in recyclability from the organisation’s point of view.

Enjoy the last edition of Packaging Europe magazine in 2024!

Libby Munford, Editor, Packaging Europe, speaks in-depth with Stefan Wiedemann, Senior Director Strategic Marketing & Business Development at Schreiner MediPharm; Sriman Banerjee, Head of Diagnostics, Software Devices & Packaging, R&D Pharma Sci, Takeda Pharmaceutical Company Limited; and Agnieszka van Batavia, VP Sustainability Pharma, Constantia Flexibles, to understand key areas of development and trends driving the industry forward.

IN THE HANDS OF PHARMACEUTICAL CONSUMERS; PATIENT SAFETY AND CONVENIENCE

For Schreiner MediPharm, patient safety and convenience have always been important prerequisites when developing its labelling solutions for the pharmaceutical industry. Constantia Flexibles declares that in today’s healthcare landscape, patient safety and convenience are paramount, and its packaging innovations are designed to meet these needs.

Sriman Banerjee, Head of Diagnostics, Software Devices & Packaging, R&D Pharma Sci, Takeda Pharmaceutical Company Limited, goes further by stating that patient safety can be classified as “a requirement by regulations, i.e. CRSF; and convenience by providing additional access features.”

Three strong opening statements from leading companies in the pharmaceutical and pharmaceutical packaging sector.

“Delicate Balances”

So what are the major aspects when developing innovative and smart solutions for pharma, keeping patient safety and convenience at the forefront?

“Having the end user in mind when designing new products is key, i.e. supporting him in easy and secure handling of medications as well as reliable tracking of the administered drugs,” shares Stefan Wiedemann, Senior Director Strategic Marketing & Business Development at Schreiner MediPharm.

He underlines key trends, “digitalization, increasing self-administration, enhanced user support and medication adherence monitoring will continue to play an important role.”

Sriman Banerjee elaborates on the first point, that the healthcare industry is embracing digital innovation, underlining that this is occurring “…at a rapid pace.

“Digital technology could be used in manufacturing, e.g., printing technologies, formats, smart packaging, or even development, e.g., simulation and modelling. This provides opportunities and challenges in terms of development, implementation, and skill sets.” He believes that over the years, we will see a seamless transition toward tech-led innovation in safety and convenience.

Agnieszka van Batavia, VP Sustainability Pharma, Constantia Flexibles, spotlights key areas in the field expected to see significant advancements over the next few years: “Serialization at the primary pack level will improve product traceability, ensuring authenticity and protecting against counterfeiting. Interactive packaging features will become more prevalent, offering track-and-trace capabilities for real-time monitoring, digital leaflets for easy access to product information, and medical and dosage details to support proper medication use and adherence to treatment regimens.”

Sriman Banerjee sums up that patient safety and convenience are delicate balances essential across demography. “They are two ends of the stick. Convenience can also drive compliance; for example, one can leverage design and graphics to easily navigate the dosing regimen, i.e., day/

night or days of the week. Smart packaging can drive convenience through alerts and tracking in the digital era.

“Safety can also be looked at from the angle of anti-counterfeiting and can be provided through a combination of physical and digital features on the pack. Further, an opportunity exists to innovate toward age-appropriate packaging, i.e., ageing consumers with lower dexterity.”

So what are some examples of the latest innovations produced by these drivers?

Advanced innovations

Each company has provided a litany of solutions which demonstrate a cross-section of the solutions in this area.

As an example, for one of Takeda’s intra-nasal products, they offer an electro-mechanical access feature to the patient to Improve safety. Similarly, for arthritis therapy areas, there are opportunities to provide easy access closure. Sriman Banerjee points out, “Opportunities may differ by format, therapy areas, and dosing.”

Constantia Flexibles points to five key areas of innovation. Agnieszka van Batavia elaborates: “High-barrier materials: We use advanced materials to protect medicines from moisture and contamination, ensuring their safety and efficacy. Child-resistant, senior-friendly lidding: Our blister packs feature lidding that is difficult for children to open but easy for seniors, providing both safety and accessibility. Anti-counterfeiting features: To combat counterfeit medicines, we have integrated anti-counterfeiting technology into our blister packs, ensuring patients receive authentic products. Easy-opening packs: Our sachets and stick packs have easy-opening features, making them more convenient for patients without sacrificing protection. Mono-polymer blister systems: We have

developed a more sustainable, recyclable mono-polymer blister system called FUNDA that maintains the same user-friendly experience.”

For Schreiner MediPharm, recent developments include, for instance, functional labels for sensitive APIs providing a gas barrier for reducing oxygen diffusion on COC syringes, or deep-freeze labels with customized light protection. These solutions are designed with the intention to enhance patient and product safety while ensuring convenient use.

When it comes to novel therapies based on mRNA or cell and gene therapies, labels have to reliably adhere to the respective drug containers while they are being stored and transported at deep-freeze temperatures. Often, the sensitive drugs also require light protection. For these applications, Schreiner MediPharm developed the Freeze-Light-Protect labels. They securely adhere to the syringe despite extremely low temperatures and enable reliable marking. In addition, the specialty labels can be provided with customized UV and light protection levels, depending on the specific requirements of the active ingredient. Additional functionalities may be integrated as well: detachable documentation labels for the vaccination cards or patients’ medical records, inspection windows for checking the syringe contents in true colour, and graduations for correct dosing of injections.

RFID-based solutions as well as integrated electronics and sensors are key enablers to further enhance patient safety and convenience. Schreiner

MediPharm provides labels with integrated NFC functionality that enable interactive applications and digital patient support.

Schreiner MediPharm’s NFC-Labels can for instance make injection pens or autoinjectors smart. By simply touching the NFC-Label using an NFC-capable smartphone, mobile websites or apps can automatically be opened to provide patients with user information, video tutorials, etc. In addition, the NFC-Label helps enhance adherence and thus improving therapy success. Patients can keep a diary and monitor their adherence while providing physicians with key data for optimizing therapies.

And sustainability?

Sustainability plays a crucial role when designing new product solutions. Schreiner MediPharm adapts existing solutions and creates new label concepts with a reduced environmental footprint. “This includes for instance functional labels made of recycled or renewable raw materials. The key objective always being to ensure the same reliable label functionality compared to standard materials,” states Stefan Wiedemann.

An example for a sustainable approach is Needle-Trap, a unique label with integrated needle protection for prefilled syringes. Compared to conventional needle safety systems Needle-Trap is “particularly environmentally friendly due to its special design. It uses far less plastic, no metal and

Sriman Banerjee: Sustainability is no longer ‘good’ but an essential part of packaging. Having mentioned that, we are in a regulated industry and need to follow the guidelines towards patient safety and convenience provided by health agencies.

Agnieszka van Batavia: Packaging that is not fulfilling its function of protecting the medicines and making sure that patients can access the medicine in a safe and convenient way, is not sustainable.

the integrated plastic trap consists of up to 50% of regranulated material. Thanks to its compact design, Needle-Trap is easy to use and requires less space during transportation and storage while generating less waste,” says Stefan Wiedemann. The latest variant of the product, Needle-Trap Secu, features an integrated seal for irreversible first-opening indication, securing the integrity of the prefilled syringe on unit level till the point of use. This eliminates the need for an additional blister pack, resulting in additional CO2 reductions. Ultimately, the label solution is a key example of a product that combines product and patient safety with sustainability.

Sriman Banerjee states that: “Sustainability is no longer ‘good’ but an essential part of packaging. Having mentioned that, we are in a regulated industry and need to follow the guidelines towards patient safety and convenience provided by health agencies. For the industry, there is a balance between the health and environmental agencies. The industry has taken steps and aligned where possible to make necessary changes towards replacing materials that are difficult to recycle, using paper as an alternative to plastics, designing for a circular economy, and industry-led take-back programs.

“While patient safety is paramount and non-compromised, convenience is a factor that needs a generational shift. For example, the e-leaflet is sustainable and convenient as you have the patient information on your mobile. However, there exists a demography that has low digital dexterity and would change over time.”

Agnieszka van Batavia goes so far as to say that there is no room for compromise when it comes to balancing sustainability with patient safety and convenience. “Packaging that is not fulfilling its function of protecting the medicines and making sure that patients can access the medicine in a safe and convenient way is not sustainable.

“Our approach integrates sustainability with safety and usability from the start, ensuring that eco-friendly materials and designs still meet the highest standards for protecting medicines and supporting patient needs.”

Better, faster, stronger

Due to the increasing digitalization trend in pharma and healthcare that we have previously touched upon, Schreiner MediPharm’s Stefan Wiedemann states that, “smartphone-based applications will become more and more important. By means of label-integrated NFC chips, drug containers and packaging can be turned smart. This offers a lot of benefits to patients since they are easy to use and ensure safe administration of the right dose at the right time. Integrated NFC enables easy access via smartphones while digital patient support and medication adherence monitoring enhances therapy success.”

The physical features and formats of pharmaceutical packaging will not undergo much of a change, i.e., blisters, bottles, vials, etc. However, Sriman Banerjee shares that, “what will change is personalization and digitization. The new emerging therapy areas are personalized and require customized

dosing and patient information. This will mean custom packaging and labelling. We see this to some extent in the US, with specialty pharma providing such services, and also in the space of cell therapy.”

He goes on to say that “Most pharma companies have similar packaging infrastructures, including chemical and mechanical testing and material characterization. However, there is development in simulation and modelling, which will be the differentiation in the future as it will lead to faster development, save costs, and de-risk quality.”

Constantia Flexibles’ Agnieszka van Batavia elaborates on several cuttingedge technologies that are also improving both patient safety and convenience in pharmaceutical packaging. “Easy peel lacquers make packaging easier to open, particularly for those with limited dexterity, while laser technology allows for precise, custom opening features. To combat counterfeiting, holograms, and security pigments are integrated into the packaging, ensuring patients receive genuine medications. Super HR printing technology enhances legibility with high-resolution labelling, and aluminium cold rolling technology strengthens packaging to maintain its protective properties.”

These innovations reflect a strong focus on delivering safer, more userfriendly pharmaceutical solutions, and it appears that digitalization will be the key driver for how we interact with pharmaceuticals, and how we protect consumers in the future.

TRACKING PROGRESS OF RECYCLING FLEXIBLE PACKAGING

Flexible packaging has many advantages. It is light and thin, and this low weight means CO2 impact from transport is reduced, and less material is used producing it than alternative packaging formats. However, big challenges around recyclability remain, as flexible packaging still isn’t recycled as standard in many countries.

Efforts are ongoing to address this and to boost the recyclability of flexible packaging. The Circular Economy for Flexible Packaging (CEFLEX) initiative, a collaboration of European companies, associations and organizations representing the entire value chain of flexible packaging, is, of course, no stranger to regular Packaging Europe readers and plays a big role in efforts to achieve fully recyclable flexible packaging. What are the newest developments in the industry, and are we any closer to meeting ambitious goals? Elisabeth Skoda speaks to Dana Mosora, workstream consultant at CEFLEX, to learn more.

Advancements in boosting recycling rates

As a full value chain collaboration consortium, CEFLEX has witnessed contributions from different angles, for example from petrochemical companies.

“They are investing R&D resources to develop recycling technologies like dissolution and chemical recycling, to put money in JVs or build capacities for ‘young’ recycling technologies. Recent examples are the recently announced collaboration between Dow and P&G on the dissolution of PE structures or LyondellBasell’s acquisition of APK AG recycling technology,” says Dana Mosora.

A range of plastic materials is set to be encompassed by the new technology developed by Dow and P&G. It will focus on polyethylene and post-

household plastic waste – especially hard-to-recycle packaging structures, like rigids, flexibles, and multi-layer designs.

Elsewhere, in 2022, EREMA Group subsidiary KEYCYCLE acquired the Cadel Deinking brand to integrate the companies’ collaborative work in deinking printed plastic waste into its product portfolio, with plans to apply the technology to post-consumer recycling streams.

Dana Mosora also highlights that brand owners and converters are embracing the CEFLEX Design for Circular Economy Guidelines and are putting on the market new packaging with improved recyclability.

“Equipment manufacturers and technology providers are focusing their efforts towards demonstrating and putting on the market new recycling

Dana Mosora

technologies in the area of advanced decontamination in mechanical recycling, like deinking and delamination and in the areas of extraction or dissolution like we had seen with EREMA’s acquisition of Cadel deinking.”

Barriers to recycling at scale

In order to be viable as a recycled material, flexible packaging has to be collected at scale and sorted for recycling at scale. Mechanical recycling has to embrace quality recycling as a goal.

“However, all these changes cost money and the cost has to be reflected in the EPR fees. These fees have to pay for the cost of recycling flexible packaging. We have to work together diligently to make these changes happen, otherwise the lack of action to implement these changes will continue to act as a barrier to recycling flexible packaging at scale,” says Dana Mosora.

To facilitate this, the ‘Designing for a Circular Economy’ devised by CEFLEX stakeholders was devised. It is a set of comprehensive guidelines to help anyone working in the flexible packaging value chain to design recyclable packaging solutions.

This five step process entails driving the collection of all flexible packaging for sorting and recycling; sorting and recycling the suitable mono-material fractions; redesigning multi-material flexible packaging to mono-materials with existing recycling streams where possible; identifying solutions and developing capabilities to sort and recycle the remaining fractions and identifying end markets for all recycled flexible packaging materials.

During the development of the initial Designing for a Circular Economy (D4ACE) guidelines, several knowledge gaps were identified that need to be filled and supported by robust test data. A testing programme was set up and is now in phase two, and Dana Mosora talks about updates and results.

“The more we advanced into testing, the more we learned and got inspired to update the Design Guidelines released in Phase 1 and to work on new design guidelines for more complex flexible packaging, made of multi-material and multi-layer type structures. More testing will be necessary to further our insight into what technology can do and how it should be applied between sorting and recycling, to increase both recycling quality and recycling rates. One thing

remains clear: technology is capable of sorting and recycling more than it currently does at commercial scale. This comes down to cost – at the commercial scale applying the technology has to also be cost efficient.”

CEFLEX guidelines and the PPWR

CEFLEX’s work is driven by the requirements of the Packaging and Packaging Waste Regulation (PPWR), as Dana Mosora points out, with the focus having shifted from developing solutions to recycling more and better towards implementation of those solutions to realize the targets of the PPWR.

“Knowledgeable experts did a deep analysis on understanding the end market’s demands in quantity and type of post-consumer recyclate (PCR). A brilliant economist in our team developed a tool which calculates the capacities of mechanical and chemical recycling needed to realize, in full complementarity, the PPWR targets and he is now looking into expanding it to the associated costs including collection and sorting.”

The PPWR places focus and urgency on higher recycling rates, recycled content and increased quality – critical pillars of CEFLEX’s Mission Circular vision. However, significant challenges lie ahead, notably ensuring a 55% recycling rate for flexible plastic packaging by 2035. How realistic is it that this recycling goal will actually be reached?

Ms Mosora is equally optimistic and concerned about the forces that might manifest as barriers along the way.

“Attaining a 55% recycling rate is very challenging and if we didn’t have examples like Italy or Belgium, which are well on their way towards 50% already, we could say that it is not going to happen. But it will happen if significant improvements and changes will be implemented in separate collection of plastic packaging and in sorting plastic packaging for recycling, from residual waste.”

There is however an added cost to implementing these changes and to building recycling capacity, which need to be addressed.

“What concerns me is that the added cost to implement those changes, if not accepted within EPR fees and paid for by the responsible industry, will become a barrier towards reaching this goal. There is another potential barrier surrounding cost, in building the necessary capacity for better

Value chain modelling

CEFLEX devised a Möbius model to determine what the flexible packaging value chain needs to look like by 2030 to meet recycled content and recycling rate targets – a mass flow model designed to answer a series of questions that CEFLEX stakeholders have asked about the effort needed to meet the PPWR targets.

Outputs from this model have shown that meeting the PPWR targets is challenging, but achievable under certain conditions, Dana Mosora says.

“We have recently improved the model so that it uses detailed data on a wide range of polyolefin packaging and combined this with a mixture of data and expert judgment on factors such as collection rates, sorting yields and recycling yields to produce estimates of the recycling rate that would be achievable at different levels of effort and what would be required to meet the recycled content targets. At our stakeholders’ request, we have also widened the scope of the model to include rigid, as well as flexible, packaging.”

Boosting flexibles recycling schemes

In recent years we have seen various dedicated schemes to recycle flexible packaging, for example in supermarkets. However, according to media reports, these do not always end up actually being recycled. What can be done to improve this situation?

Dana Mosora points out that we need collection, sorting and recycling at scale at a national level, as harmonized as possible.

“This is because of the importance of the economy of scale for the relatively young plastic collection-sorting-recycling industry in many of the EU countries. The way I look at those different models being tested or experimented on, they are pilots for different concepts which ultimately should become part of the national, harmonized, model of collection-sorting-recycling. It is important to optimize the cost at each level of the value chain, as a means to make the whole system work towards a successful implementation of the PPWR.”

polymer science.

“However, this requires time: creating new polymers with new properties takes many years and the R&D brief for these new developments was written not long ago.”

When it comes to significant developments and next steps for the coming months and years, she is looking forward to the EU legislation to clear the way for chemical recycling to accelerate its development.

“The Mass Balance debate shall end and make room for clarity in how investments can be made, and how technologies can move forward along the learning and development curve and deliver the yield and economics which will enable them to become the contributors to a Circular Economy which fits into the Green Deal framework. Chemistry science and technology can deliver but as mentioned above, time is needed for scientists and technologies to progress in their work. I expect a similar development for all the other young technologies like dissolution which need focus on further developing the technology to deliver in an economic way.”

PATHWAYS TO A SUSTAINABLE FUTURE FOR PACKAGING – A LOOK BACK AT THE SUSTAINABILITY AWARDS

Innovative, disruptive, trendsetting, the future – these are just a few words delegates used to describe this year’s Sustainable Packaging Summit that took place on November 12th and 13th in Amsterdam. The Sustainable Packaging Summit aims to create a ‘Davos’ dedicated to making packaging fit for purpose in a rapidly changing world, and we are proud to create a space for the packaging value chain to come together and forge paths towards a more sustainable future.

ATthis year’s Sustainable Packaging Summit in Amsterdam, we welcomed 600+ delegates, 55 sponsors and exhibitors, 100+ partners and influencers. The event will be back, bigger than ever, with an extra day of content, more speakers, exhibitors, and industry professionals from 10th – 12th of November 2025 at the Jaarbeurs Event & Exhibition Centre in Utrecht in the Netherlands.

An integral part of the Sustainable Packaging Summit is Packaging Europe’s Sustainability Awards. The winners of the ‘Nobel Prize’ for sustainable packaging innovations were announced at our sold-out awards dinner. Congratulations to all our finalists and winners, it’s encouraging to see the breadth and depth of innovation in our industry.

Best Practice – GemCorp Recycling Initiative by Gemini Corporation

GemCorp was founded to establish a formal collection network and improve the livelihoods of informal waste reclaimers. As it joins forces with waste workers, it aspires to help develop safe practices, provide relevant training and protective gear, and streamline collection methods. Every year, it collects and recycles over two million tonnes of waste and saves 2.4 million tonnes of CO2.

It also contributes to shifting perceptions about waste, recycling, and the environment and provides high-quality, cost-effective plastic recyclate

to reduce the demand for virgin plastics. Meanwhile, its blockchain-based ‘ReMake’ application plans to unlock end-to-end traceability, transparency, and circularity in the recycling value chain.

Climate – NextGen Furnace by Ardagh Glass Packaging

The facility in Obernkirchen, Germany, uses electrodes to melt glass with direct electrical heating, thus replacing fossil fuel with renewable electricity. In turn, it expects to reduce Scope 1, 2, and 3 carbon emissions by as much as 69% for every 330ml amber glass bottle produced.

It also plans to reduce its required energy consumption by using up to 70% recycled glass cullet, and expects to reduce CO2 emissions by 5% for every 10% increase in cullet used. A life cycle analysis (LCA) reveals that every 330ml bottle reduces 97.1g of CO2 across Scope 1, 2, and 3 emissions.

Driving the Circular Economy – Henkel

Henkel won the top prize for repurposing PET blisters and trays – traditionally considered to be low-quality sources of recyclate due to their complex, multi-layer construction – into a 100% PCR, circular PET film sourced from household waste.

The film comprises more than 80% recycled PET tray, all of which are sourced from German household waste. The final film is applied to the blister pack for Henkel’s WCFrisch ProNature WC cleaning product.

The100% recyclable and flexible paper-padded envelope for e-commerce deliveries is designed to phase out plastic-based bubble-wrap padding without compromising on shock absorbance and product protection.

This innovation utilizes the same paper as Amazon’s existing delivery bags, alongside padding from corrugate – a move set to secure the pack’s resilience and keep products safe in transit. The flexibility of its open-flute padding helps the pack fold around the product’s shape, preventing it from shifting inside the mailer and negating the need for void fillers.

Recyclable Packaging – GreenLabel BlockOut by Brook + Whittle

Since coloured PET is considered a low-value resin, GreenLabel BlockOut, an APR-recognized recyclable, light-blocking shrink sleeve is designed to enable manufacturers to transition into clear PET without compromising on light-blocking performance. This solution is able to block up to 99% of light from 200nm to 900nm.

At the same time, it achieves a 100% sorting rate through NIR sortation equipment when applied to a clear PET bottle (according to the company’s MRF studies), thus keeping plastic out of landfill.

Renewable Materials and Overall Winner – Upfield

This solution uses paper from a PEFC-certified supplier and has received Conventional Plastic Free Certification.

Fiber Labelling, the pack is mono-material and therefore recyclable. It does not have a plastic liner, meaning it can be cleaned, dried, and recycled alongside paper and cardboard household waste, as verified by a leading European recycling company.

Machinery – RecycleOS by EverestLabs

RecycleOS, an AI-powered robotics solution for material recovery facilities (MRFs), analyzes the waste stream coming into a facility and recovers twice to three times the amount of material that traditional sorting methods can.

Reaching an accuracy of over 95%, this solution is set to keep recyclable materials within a circular economy and enhance a plant’s efficiency by 30-50%. It can also analyze the value, volume, and types of materials entering and exiting a plant – providing the necessary data to improve operations and increase material recovery.

Pre-Commercialized Climate – PulpaTronics

PulpaTronics’ recyclable, metal-free, chipless RFID tags laser-induce a carbonbased conductive material onto paper and store information in the geometric pattern of the conductor instead of using a microchip. Therefore, the tags negate the need to mine metal, cut down on the resources required to produce them, simplify manufacturing, and streamline recycling.

They are set to halve the price of conventional RFID tags, as they cut down on transportation, material, and energy-related expenses.

Renewable Materials and Overall Winner – Upfield

Pre-Commercialized Driving the Circular Economy – Husky

Pre-Commercialized Driving the Circular Economy –Husky

Husky’s designed-for-circularity PET closures are manufactured from bottle-grade PET and are fully compatible with existing PET recycling streams, which simplifies collection, avoids stream contamination, and increases recycling yield. Therefore, it hopes to increase the availability of recycled PET within the economy and facilitate a circular transition.

The closure enables further opportunities for lightweighting than conventional solutions due to its material properties. It can also be tethered in line with EU legislation.

Pre-Commercialized Recyclable Packaging –Ecotwist by John West Foods

Aiming to avoid 65 tonnes of PET plastic shrink wrap in John West’s ‘tuna tower’ formats every year, Ecotwist replaces plastic and carton wrap with a ‘naked’ multipack joining five steel cans of tuna with a recyclable aluminium foil sticker.

This ‘Smartstrip’ is perforated, meaning consumers can twist and remove the sticker with ease. It has been independently verified as fully recyclable and can be recycled in one piece with the steel can via kerbside recycling in the UK.

The solution was developed in partnership with Touch Design, CCL Label, Schubert Packaging Systems, Karville, Secma Cabon, and Concept PG.

Pre-Commercialized Renewables – Avery Dennison and Bioenzymatic Fuel Cells (BeFC)

Their organic battery based on Avery Dennison materials replaces non-disposable coin and button cell batteries with a compostable and/or recyclable energy solution for microelectric IoT applications (e.g., smart consumer labels).

Pre-Commercialized Recyclable Packaging –Ecotwist by John West Foods

sugars and oxygen into electricity. In doing so, it reduces demand for the rare-earth materials and toxic electrolytes used in conventional battery technologies, substituting them with organic and widely available alternatives.

Readers’ Award – chosen by Packaging Europe subscribers

This year, you gave the award to Vytal and its fully digital experience for reusable food and drink containers.

A full-scale pilot took place among the 80,000 participants of the OMR Festival 2024 in Hamburg. Using individually traceable cups and food containers optimized the efficiency of the reuse system, while its unmanned return processes simultaneously reduced the strain on venue staff and cut down on the time consumers spent waiting or at checkout.

Outstanding Contribution award – the GreenBlue team

The trophy was awarded collectively to the GreenBlue team, after judges nominated several different individuals at the pioneering non-profit organization based in the USA.

GreenBlue has played a pivotal role in facilitating value chain coordinated progress across the packaging value chain in North America, initiating transformative projects such as the Sustainable Packaging Coalition and the How2Recycle label.

Submissions for next year’s awards will open in January 2025. Find out more about the application process here: https://packagingeurope.com/sustainability-awards

THE INNOVATION OUTLOOK FOR 2025

What’s on the innovation agenda for the packaging industry in 2025? We asked some leading industry experts to give their predictions on some of the biggest topics impacting the sector today.

THE OPPORTUNITIES FOR FLEXIBLE PAPERS

Patrick Poitevin, former Principal Scientist at Mondelez International and founder of Advisory4Pack

The focus for flexible paper development is weight, barrier and opacity / translucency. The lighter the flexible papers, the less weight for inbound and outbound, the smaller the gauge, then the cheaper flexible paper will become. Of course, functionality and machinability – for both forming and sealing – have to match the current asset needs and retro fit is important for any packaging format. Barriers (water vapour and oxygen transmission), mineral oil, water and grease resistance have been a challenge so far. To maintain the fibre ratio, along with bio-based coatings or additives, would provide the barrier properties which are currently achieved with plastic.

The lighter the paper, the more translucent, but not every brand owner wants their product to show through the packaging material. In contrast, some developments are ongoing to obtain a highly translucent paper to show off the product. 2025

REUSE AND REFILL

Willemijn Peeters, founder of Searious Business

is set to be a year to remember in ‘Reuse History’. An almost serendipitous mix of policy support, technological leaps, and public-private partnerships is creating a pivotal moment for the refillable and reusable packaging movement. Europe is building momentum with landmark policies like the EU’s Packaging and Packaging Waste Regulation (PPWR), giving companies a unique chance to rethink product delivery on a fundamental level. While the PPWR targets may not be as high as some of us hoped, it’s crucial to remember these are minimum requirements – countries and companies can still aim higher. Plus, there’s a growing mountain of evidence supporting both the sustainability and economic viability of reusable packaging systems at scale. We’re also seeing an

explosion of innovative solutions, like the UK’s Refill Coalition, bringing refillable packaging squarely into the mainstream.

At Searious Business, we’re not just observing this transformation but actively contributing to it across Europe and beyond. Through the EPPIC Business Development programme, we’re helping to build reusable packaging systems in regions like Sub-Saharan Africa and Central America, where plastic pollution remains a serious day-today concern. This work, combined with the Global Plastic Treaty’s upcoming commitments, everything crossed, makes me confident that by 2025, the shift toward reuse and refill systems will be unstoppable, taking us closer to a genuinely circular future in packaging where nothing becomes waste.

RECYCLING TECHNOLOGY/RECYCLABILITY

Dana Mosora, CEFLEX workstream consultant

Ilookat the coming years of plastic recycling with excitement, not only because I am an optimist by nature but because, frankly, the only way forward for the industry to strive is via an acceleration of innovation and, most importantly, the implementation of innovation at scale.

The recycling industry has to, and has started to, upgrade itself with quality recycling type technologies: advanced washing, deinking, extrusion with double filtration, deodorization of different kinds.

But this is far from being enough. What we need is more advanced decontamination in mechanical recycling with technologies like delamination; Saperatec has launched its 39’000T plant in Germany and we need that technology to go commercially beyond carton beverage packaging into multi-material multilayer flexible packaging. With continuous R&D it will.

Then, there is delamination with deinking like the Fych technology which is now looking closely into mixed polyolefins type flexible packaging structures, because this is what will help industry increase both recycling quality and recycling rate; again, further R&D work is going to bring that technology where we need it to be.

Another advanced decontamination in mechanical recycling which caught our attention is extraction with super critical CO2. A well-proven technology in wine or drugs production, it is now being demonstrated by a startup launched by the Institute of Plastic Technologies in France, in partnership with others. The innovation is in how they demonstrate the technical and commercial feasibility by providing real life proof of the quality of the outcome using the feedstock of various customers.

And to end, I wish to highlight the good progress delivered by dissolution technology providers who run real life pilots or commercial plants

BIOPLASTICS INNOVATION OUTLOOK

Pia Skoczinski, Senior Expert, Technology & Markets, nova-Institute

Bioplastics or biopolymers are, dependent on the definition, either bio-based or biodegradable or both. Considering worldwide bio-based, non- and biodegradable polymers production capacities have reached 5.2 million tonnes in 2024, with an actual production of 4.1 million tonnes –reflecting an average capacity utilization rate of 80%.

For 2025, global production capacities are expected to increase by about 1 million tonnes to 6.2 million tonnes. The main drivers for this increase are the bio-based, biodegradable polylactic acid (PLA) and polyhydroxyalkanoates (PHA) and the bio-based, non-biodegradable epoxy resins and polyethylene (PE).

Production capacities of PLA in 2025, which is mainly used for flexible and rigid packaging, will increase in Asia, while capacities in North America and Europe will remain constant. Similar to PLA, PHA is mostly used in the flexible and rigid packaging but also in consumer goods. Next year, production capacities of this bio-based and biodegradable polymer will

increase in Asia, North America and Europe, while installed capacities in South America and Australia / Oceania will stay the same.

PE capacities will increase mainly in Asia and North America with installations of new production plans. Currently installed capacities in South America are expected to remain constant. Bio-based, non-biodegradable PE is mainly used for flexible packaging.

The current market and trend report “Bio based Building Blocks and Polymers – Global Capacities, Production and Trends 2023–2028” is available in full length as well as a freely available short version here: https://renewable-carbon.eu/commercial-reports. With the allowance code Winter2024 you will get a 20 % discount on this and 28 other market reports from 20 November 2024 – 31 January 2025.

The latest nova market and trend reports will be presented on 28 November 2024 in a free nova Session: https://events.renewable-carbon.eu/events/.

E-COMMERCE

Nedim Nisic, Mondi Group eCommerce Director

Looking ahead to 2025, I believe that e-commerce packaging innovation will continue advancing with an emphasis on sustainability, efficiency, and consumer convenience. The shift towards lightweight materials and the transition from plastic to paper-based solutions epitomizes this trend, such as our latest innovation, the Protective Mailer. In response to customer demand for right-sized, easily recyclable packaging that minimizes waste and ensures damage-free delivery, Mondi’s e-commerce team collaborated closely with Amazon’s engineers and packaging scientists to create sustainable packaging that offers protection equivalent to traditional bubble-wrap plastic-padded envelopes.

Further, we anticipate that packaging tailored for automated fulfilment systems and optimized for logistics will increasingly streamline operations, cutting material waste and costs. Automation in fulfilment is a trend we see becoming ever stronger in e-commerce.

In summary, innovations improving our customers’ supply chains – designed to protect products and elevate the consumer experience with convenient handling and disposal options – will continue to be at the forefront. Collaboration across the industry will be vital in developing solutions that can address these challenges holistically, advancing e-commerce packaging towards a more sustainable future.

PRINTING TECHNOLOGY

Rachael Satchwell, Global Food Sector Manager, Domino Printing Sciences

Theinnovation horizon for packaging printing technology is largely shaped by demands from brands and manufacturers on the one hand and legislative changes driven by regulators on the other. With this in mind, we see two key themes that will have a significant influence on developments in printing technology for the year ahead: packaging changes aimed at making products more sustainable or recyclable and the global drive towards onproduct 2D codes, including QR codes powered by GS1, for environmental, consumer engagement, accessibility, and regulatory reasons.

We are already seeing several key trends emerge in the drive towards sustainable packaging materials, including paperization for items such as flexibles and trays, developments in new compostable materials, and the move to mono-material plastics. From a product printing perspective, all these trends can present challenges for print technology providers, who need to ensure that their products are equipped to safely and effectively handle new materials without compromising code quality, durability, or reliability while also fulfilling requirements in terms of food-contact safety, recyclability, and compostability, where necessary. For the year ahead, we can foresee more technological developments to this end, including new food packaging safe and compostable inks, and increasing interest in laserbased technologies that add nothing to the pack.

Alongside this, the global drive towards 2D codes, and GS1’s move to see 2D accepted at the point of sale, will have a significant effect on other technological developments. It comes at a good time: businesses that already require technology upgrades due to sustainability commitments can save time and effort by ensuring that their lines are also equipped to

of fast-paced, high-resolution on-product 2D codes for specific sustainable

combination of product handling, coding and marking, and manufacturing vision systems.

AI/CONNECTED PACKAGING

Stefan Hilss, CEO Linked2Brands

Whenspeaking with industry peers about the future of packaging, ‘connected packaging’ has emerged as one of the global mega trends, alongside the omnipresent drive for ‘sustainability’.

In my view this is because connected packaging is poised to address a wide range of challenges across the industry, making it an essential element in any strategic packaging discussion. Among the most pressing drivers of adoption today is the need for compliance with new regulatory standards, particularly the PPWR and the Green Claims Directive, both key components of the European Green Deal. As companies face stricter data reporting and consumer information requirements with limited space on physical packs, connected packaging offers the technological exit out of this otherwise dead-end street. However, ensuring compliance is just one of

deliver. By creating an interactive bridge between physical products and digital experiences, it opens unprecedented opportunities for brand loyalty and consumer trust, while also addressing logistics and sustainability challenges. Whether through visible or imperceptible codes, brands can offer consumers and other stakeholders in the value chain instant access to personalized content, product authenticity verification, detailed sustainability credentials, process information and much more.

Global initiatives such as GS1’s Project Sunrise and HolyGrail 2.0 have raised awareness beyond consumer engagement and while the need for regulatory compliance may be the driver for initial adoption, the technology’s versatility in supporting supply chain efficiency, fighting counterfeiting, and enabling dynamic consumer engagement is reshaping how brands communicate and engage

Looking ahead, I believe connected packaging is set to become much more than just a compliance tool – it will be a ‘must have’ to stay compliant and relevant in the marketplace. For forward-thinking brand owners, the question is no longer whether to implement a connected packaging strategy, but how to leverage its full potential, meeting the demands of increasingly digitally savvy consumers, compliance and full transparency in the value

WHICH PACKAGING CARES FOR YOUR HEALTH?

Jenni Krohn from Avery Dennison and Sylvia Kaiser-Kershaw from NXP Semiconductors bring us the latest in our Wider View series.

Managing illness can be tough for many patients. This story follows Alex, who lives with a chronic health condition, and shows how a simple idea for drug packaging can help her manage her medication and improve her health.

Alex’s medication worries

For Alex, every day should start and end with taking her medications. She knows that not taking her medicines can lead to adverse effects, but sometimes she makes mistakes in the self-administration, or simply forgets. Her challenges are familiar:

• Did she or didn’t she? Alex has a busy family and work life and often forgets to take her medications on time. She occasionally has difficulty self-injecting as she lacks clear instructions, leading to health risks.

• What if they are fake? She buys her medicines online and worries about them being genuine. She hears about the rise of counterfeit drugs, which makes her hesitant to take new refills. – What if the drugs have expired? She doesn’t always check the packaging and fears taking something that is out of date.

• Is it working? As her condition feels stable, Alex doesn’t speak to he healthcare provider very often. She sometimes wonders if she is up to date with the latest progress on managing her condition effectively.

Common problems that cost billions

Medication non-adherence affects millions of patients globally. It is estimated that 50%1 of patients with chronic illnesses do not take their medications as prescribed, leading to significant health risks and increased healthcare costs. The cost to the global healthcare system is estimated to be $528 billion2 annually. Patients may be non-adherent for various reasons, such as lacking usage directions, forgetting doses, fear of side effects, financial worries, or lack of symptoms. This can lead to treatment failure, increased hospital readmissions, additional medical/surgical procedures, and excess healthcare costs. The rise of counterfeit drugs made from substandard or falsified ingredients is another major issue, posing serious health risks. The World Health Organization (WHO)3 has estimated that 10% of global pharmaceutical commerce, or $21 billion worth, involves counterfeit drugs. Such drugs

may result in adverse events, treatment failure, resistance, toxicity, and even death. This problem is aggravated by the complexity of global supply chains and the increase in online pharmacies.

Unsurprisingly, there is a direct correlation between the demand for a drug and the availability of unsafe or counterfeit supplies. The gray market includes drugs diverted from authorized channels. These products could be authentic but are no longer safe for consumption due to improper storage, expiration, or counterfeit that have been altered, for example by being diluted or made with cheap ingredients.

Helping patients with smart packaging

Intelligent labels are giving packaging an active role in healthcare. Both primary packaging, for example medicine vials, syringes, pens, and autoinjectors, as well as secondary packaging cartons can have an intelligent label applied that includes a Near Field Communication (NFC) tag.

For patients this opens up a world of support, both practically and emotionally. Using their smartphones patients can digitally authenticate drugs equipped with secure NFC technology, and detect tampering. With just one phone tap on the medication packaging, a patient like Alex can confirm if her drugs are genuine. This quick, clear, unambiguous result gives instant peace of mind. Through interactive applications, coupled with a website or an app, Alex can get easy access to medication information, self-application guidance and track adherence using the same technique. She can access information such as dosage instructions, warnings and contraindications, expiration dates, and storage guidelines upon a simple phone tap. For tracking and

monitoring her treatment over time, a connected drug delivery device with electronic sensing function and coupled with a companion app, can help her capture key information such as dose, date and time, rather than manually recording data. She can also receive an alert when her next dose is due or missed. Such access to product and application information empowers her to track, comprehend and manage her treatment effectively. This collected adherence data can also be shared with her healthcare provider, keeping them informed of her treatment’s progress.

What is NFC technology and how does it work?

NFC is a short-range wireless connectivity technology that allows the transfer of data between two NFC enabled devices, such as a NFC tag and a mobile phone. It uses two main elements: NFC tags and NFC readers. NFC tags contain small microchips that differ by memory sizes, functionalities and security attributes. They do not require batteries as they are powered by the reader’s field. NFC readers are used in smartphones, but can also be built into reusable medical devices to allow communication between the device and medication. This makes them suitable for many battery-free applications.

Secure NFC tags can greatly enhance product authentication for Healthcare. Authentication involves advanced security checks based on a tag’s data and credentials, such as passwords and cryptographic functions. Authorization then verifies permitted access to a device, its application, and data. By utilizing NFC tags, patients can actively participate in the process by easily authenticating products before purchasing or taking them by using their smartphones.

• Short-range data exchange between tags and readers (up to 10cm, less with smartphones)

• Contactless operation at 13.56 MHz, no battery required

• Working with smartphones (native Android, iOS) – app-free or app-based

• Or, automated communication between medication and medication device

• Status awareness such as first opening indication or sensing possible

• Dual-interface tags support also wired connections e.g. to a microcon troller, sensor in device

Which medicines benefit most from connected packaging?

Conditions and medications that require strict adherence to their relevant treatments have the most to gain. Patients and healthcare professionals both need in-depth information, as the consequences of non-adherence can be severe. Many medications, such as insulin for diabetes, biologics for skin conditions, and disease-modifying therapies for MS, are often injectables, which can make self-administration more difficult.

Chronic conditions often require multiple medications, strict adherence, and careful monitoring:

• Diabetes

• Cardiovascular Diseases

• Weight Loss

• Skin Conditions

• Multiple Sclerosis (MS).

NFC secured packaging offers an effective way to protect patients from the harmful effects of counterfeits, safeguarding their well-being. Espe-

ing. By using NFC technology, manufacturers can provide clear, irrefutable proof of a product’s authenticity directly to the patient.

Benefits

for healthcare providers and pharma companies

Smart drug packaging optimizes patient care, reliably protects product and patient safety, and ultimately helps reduce the cost of healthcare. From source, throughout the supply chain to the end patient, packaging using connectivity technologies such as NFC enables integration of product-specific information. This enables a transparent supply chain, facilitates communication with patients and medical staff, monitors adherence to therapy, and provides transparency regarding product usage in the market.

1. Improved patient outcomes

By helping patients like Alex manage their medications more effectively, pharmaceutical companies and healthcare providers can ensure better health outcomes and reduce complications related to non-adherence.

2. Enhanced safety

Digitally authenticating medications equipped with secure NFC tags via smartphone helps prevent the use of counterfeit drugs, ensuring product and patient safety. Tags with electronic first opening indication enable detection of possible tampering of packages upon a tap. A patient like Alex receives immediate feedback indicating the authenticity and integrity of the drug, while the pharmaceutical company gains valuable information such as geolocation to monitor the drug supply chain and combat potential gray market activities.

For reusable medical devices, the “lock-and-key” principle ensures device recognition of original manufacturer consumables, guaranteeing optimal performance and safety. The reusable device is equipped with an

NFC reader to read a consumable equipped with an NFC tag automatically and contactless. The data stored on the NFC tag alerts the user of wrong, counterfeit or expired products, and increases patient safety during selfadministration, by avoiding application errors. Consumable tag data can also be used for automatic device setup, eliminating manual configuration.

3. Better data for treatment effectiveness

With a patient’s permission, therapy adherence data sets with corresponding medication batches and timestamps can be stored, facilitating in-depth data analysis and processing. Information can be shared with one’s clinician, allowing them to monitor their patients more closely and adjust treatment plans as needed, leading to more personalized and effective care. Proven drug effectiveness and better outcomes also benefit the pharmaceutical manufacturer, especially when dealing with outcome-based reimbursement programs.

4. Cost savings

Smart drug packaging can cut healthcare costs by verifying drug authenticity and promoting patient adherence. It reduces the risk of adverse reactions from counterfeit drugs, prevents unnecessary hospitalizations, and helps improve patient adherence.

5. Direct patient engagement:

With the aid of NFC technology, pharmaceutical companies can communicate and build direct relationships with patients like Alex. This direct channel can enhance patient education and be used for practical services, such as refill reminders, leading to more informed and effective treatment plans. Pharmaceutical companies will also gain access to data and insight into customer behavior previously out of their reach. Additionally, it presents the potential to build trust, protect brand reputation and explore direct-to-consumer business models.

What connected medicine packaging means for healthcare

We believe in more personalized, patient-centric and safer care. We see how technology can bridge the gap between patients, healthcare providers, and pharmaceutical companies.

For patients, connected packaging can mean better physical and emotional support to manage their chronic medical condition.

Imagine how Alex’s healthcare experience could be enhanced with smart packaging and a dedicated app on her phone. The app goes beyond sending reminders to take medications. With it, Alex can now conveniently track her adherence over time, review her treatment history, and monitor her progress, empowering her to take a more active role in managing her health. It also provides a convenient way for Alex to consult with her doctor remotely, a crucial option when she is hesitant about starting new medications or concerned about side effects. Additionally, the app facilitates connections with individuals facing similar conditions, offering her moral support, practical advice, and a sense of community.

From helping patients with adherence to providing a convenient way to sign up for a safe, automated refill service, to reliably verifying a product is genuine and safe to use, smart technology including connected packaging will help millions of patients like Alex.

For healthcare providers, real-time data collection and remote monitoring pave the way for more adaptive and responsive treatment plans, tailored to individual patient needs. For pharmaceutical manufacturers, this innovation promises greater transparency, security and integrity within the supply chain, while direct communication channels foster loyalty to the drug and the company among physicians and patients.

Ultimately, this leads to improved health outcomes, cost savings, and a more efficient healthcare system. Smart packaging has the potential to support new standards for medication safety, adherence, and patient engagement shaping a more interconnected future for healthcare.

References:

1: M.T Brown and J.K Bussell (2011) Medication Adherence: WHO Cares?

2: Watanabe JH, McInnis T, Hirsch JD. Cost of Prescription Drug-Related Morbidity and Mortality. Ann Pharmacother. 2018 Sep;52(9):829-837. doi: 10.1177/1060028018765159. Epub 2018 Mar 26. PMID: 29577766.

3: A study on the public health and socioeconomic impact of substandard and falsified medical products. Geneva: World Health Organization; 2017. Licence: CC BY-NC-SA 3.0 IGO. Link: https://iris.who.int/bitstream/ handle/10665/331690/9789241513432-eng.pdf;sequence=1

Company Profiles

Avery Dennison Corporation is a global materials science and digital identification solutions company that provides branding and information labeling solutions, including pressure-sensitive materials, radio-frequency identification (RFID) inlays and tags, and a variety of converted products and solutions. The company designs and manufactures a wide range of labeling and functional materials that enhance branded packaging, carry or display information that connects the physical and the digital, and improve customers’ product performance. The company serves an array of industries worldwide, including home and personal care, apparel, e-commerce, logistics, food and grocery, pharmaceuticals and automotive. rfid.averydennison.com

NXP Semiconductors is a trusted partner for innovative solutions in the industrial, automotive and Internet of Things, mobile and communications infrastructure markets. The company’s “Brighter Together” approach combines leading-edge technology with pioneering people to develop system solutions that make the connected world better, safer and more secure. The company has operations in more than 30 countries and posted revenue of US$13.28 billion in 2023. www.nxp.com

PERFECTFOLD: THE FUTURE OF LIQUID CREASING FOR CORRUGATED BOARD

According to Robatech, its PerfectFold system for liquid creasing will revolutionize the folding process for corrugated cardboard by enhancing its efficiency and quality – but how? David Trinkner, Business Development Manager Graphic & Converting, gives us the lowdown in this edition of our ‘In Conversation With...’ series.

First of all, walk us through PerfectFold’s creasing system; how does it enable such precise folding of flat corrugated board?

PerfectFold is a system that creases corrugated cardboard by applying a special creasing liquid onto the two fold lines in a contactless process. The softening of the board allows for very precise folding.

PerfectFold is mainly made up of two jetting heads, a pump, two liquid containers for changeover on the fly, and an I/P converter that ensures the correct amount of liquid is applied according to the production speed.

On that note, what does PerfectFold do that conventional creasing systems can’t? How do they compare?

PerfectFold improves fold precision while simplifying the entire folding process. The system reduces gap variance and fishtailing significantly. This minimizes process disruptions during box erection. Furthermore, consistency in box dimensions is exceptional. Inserts fit precisely.

Creasing corrugated cardboard with a liquid eliminates the need for mechanical pre-creasing. The flute is simply softened but remains intact. Therefore, the

pressure on the creasing tools can be decreased, which results in a noticeable benefit: tool wear time doubles or even triples.

Less pressure on the creasing tool also dramatically reduces the risk of inner line cracking. We are often asked if the creasing liquid reduces box stability, but the box comprehension tests (BCT) we have conducted so far demonstrated even a 3% to 5% better box stability compared to conventional creasing.

Robatech has designed its SpeedUp creasing fluid for the PerfectFold system. Could you tell us more about this fluid and how it works?

SpeedUp was specially developed for PerfectFold. The creasing liquid penetrates the corrugated board very quickly, enabling high-speed machines to operate at maximum capacity.

SpeedUp leaves no marks after folding and is FDA-approved, making it suitable for cardboard used in food packaging.

How easily can customers integrate PerfectFold into their existing packaging lines, and how might their operations benefit from this solution?

We typically install PerfectFold within a scheduled one-day maintenance period. It’s easy to integrate. Since PerfectFold reduces the cardboard’s stiffness, operators can run the process without pre-creaser and less contact pressure of the creasing tool.

From an environmental standpoint, what can packaging manufacturers expect from this system?

As the folding accuracy is exceptional, especially with double-wall cartons or big boxes, the manufacturing process becomes more stable. That means less production rejects due to consistently sized boxes.

Approximately 90% of all 0201 corrugated boxes are destined to be automatically erected, filled, and sealed by gluing. Packaging manufacturers can anticipate a reduction in customer complaints.

Overall, why would you recommend PerfectFold to customers in the fibre-based packaging sector?

PerfectFold revolutionizes the creasing process, making it more stable, simple, and more sustainable, while also enhancing box quality.

To my knowledge, and what we have experienced so far in the market, no other system can reduce gap variance, fishtailing, and fold cracking to the same extent as PerfectFold.

It’s a true game-changer for packaging manufacturers looking to elevate both efficiency and quality in their production lines.

WHERE DOES CHEMISTRY FIT INTO THE PAPER PACKAGING TRANSITION?

In this edition of our ‘In Conversation With…’ series, Joonas Hokka and Matthias Krätschell – Kemira’s manager for Applications and Marketing EMEA and manager for Business Creation EMEA, respectively – unpack the role of chemistry in packaging’s paperization trend, especially where it relates to recyclable barrier coatings.

Walk us through some of the chemicals used in Kemira’s barrier coatings. What benefits do they bring to a fibre-based pack?

Chemistry is the unsung hero in the transforming packaging industry. Think of it as an invisible enabler: it allows fibre-based packaging materials to meet demanding performance requirements, especially in applications like food packaging.

As a dedicated partner in the ongoing paperization of packaging, we’re focused on developing sustainable chemistry solutions that power the shift from plastic to functional paper, board, and molded fibre packaging.

Our Kemira FennoGuard™ barrier coatings are a prime example. We have a broad portfolio of water-based dispersion coatings to provide essential protective properties – from oil and grease resistance to water vapour control – and provide recyclable, safe alternatives to PE layers and fluorochemicals in fibre-based packaging, such as food service packaging, wrapping papers, pouches, and cup stock.

Our portfolio is designed to match different needs, whether short- or long-term grease resistance or reliable liquid holdout with specific converting properties such as heat sealability. Importantly, all our coatings are designed with recycling in mind and are easily repulpable.

Our barrier coatings have proven runnability with all typical coating and printing application methods and meet versatile converting requirements such as folding, gluing, and sealing. Our coatings are based on an open formula, which allows cost-efficient production of innovative barrier-coated products onsite. By working closely with partners throughout the value chain, we can optimize solutions for specific end-use requirements and to suit individual production lines and processes.

How do Kemira’s barrier coatings maintain their functionality and safety in contact-sensitive applications while staying recyclable?

Food safety is non-negotiable when developing solutions for food packaging. This means balancing functionality, sustainability, and safety, and requires significant attention to regulatory compliance.

Our FennoGuard™ barrier coatings are approved for direct food contact and comply with FDA, BfR, and GB regulations. Additionally, they provide crucial protection against the migration of harmful mineral oil residues in packaging made from recycled fibre.

Our dedicated Product Stewardship and Regulatory Affairs team plays a crucial role in navigating this complex, evolving landscape. They help us stay ahead of regulatory developments, ensuring compliance with current standards and anticipating market demands.

Ultimately, brand owners bear the responsibility for the safety of packaged food. Success requires close collaboration and transparency across the value chain. This also ensures new solutions are practical and costefficient for real-world applications.

One area we’re working in is PFAS replacement. While we don’t have any PFAS-containing products in our own portfolio, we’re following the discussion around these ‘forever chemicals’ to support the transition away from these substances.

A good example is our participation in the EU and SERI-funded Zero F project. Along with 11 other industry and research partners, we develop coating alternatives to harmful PFAS compounds in food packaging, based on renewable raw materials. Our role focuses on barrier chemistry, its application, performance, and safety. We’re validating that new

Joonas Hokka Matthias Krätschell

solutions are feasible, meeting functionality and other requirements for end use while ensuring that they can also be efficiently applied to the packaging material.

What are Kemira’s biomass balance solutions? What do they mean for fibre-based packaging?

At Kemira, we’ve embraced the biomass balance approach as an immediate and practical step forward. It’s essentially a drop-in solution that helps reduce the use of fossil-based raw materials while maintaining product performance. At the same time, we continue developing novel renewable solutions.

We launched our first biomass-balanced alternatives in 2021, starting with polymers for water treatment, retention, and drainage applications. Since then, we’ve expanded the portfolio to include a range of products.

All these products contain at minimum 50% of renewable carbon through mass balance attribution. This is achieved through the increased use of renewable raw materials at the beginning of the production value chain.

All our biomass-balanced products and their manufacturing sites are certified according to ISCC PLUS standards. This reduces fossil-based raw materials in the value chain and supports the reduction of carbon emissions without disrupting established processes.

Tell us about Kemira’s ongoing projects to develop renewable barrier solutions.

We’re combining high barrier performance with enhanced sustainability, enabling paper and board packaging and molded fibre applications to meet demanding end-use requirements while being fully renewable. These innovations offer multiple end-of-life options, from recyclability to compostability and biodegradability, giving manufacturers flexibility to meet varying requirements for packaging materials.

One avenue focuses on harnessing the potential of PHA in barrier coatings for fibre-based packaging. This range of renewable aqueous dispersion barrier coatings is developed utilizing Danimer Scientific’s advanced Nodax™ technology.

PHA has an excellent biodegradability profile, comparable to that of natural polymers, which makes it ideal for enhancing the functionality of fibre-based packaging.

On another front, we’re working to develop polysaccharide-based barrier coatings based on IFF’s innovative Designed Enzymatic Biomaterial™ platform. This approach enables the production of new renewable polymers with enzymatic polymerization, opening possibilities for performance additives in fibre-based packaging.

In a way, this work represents the ‘last mile’ – eliminating the remaining non-renewable content from fibre-based packaging while maintaining the functionality both brands and consumers expect.

The Packaging and Packaging Waste Regulation is close to being enforced, and the Single-Use Plastics Directive revision will take place in 2027. How could Kemira’s solutions help customers stay ahead of

Our position is clear: we believe fibre-based packaging is crucial in creating a circular society, and recyclability must be at the core of future packaging solutions. We support all efforts that drive this transition and focus on developing solutions that help the packaging value chain meet

This regulatory evolution is accelerating the shift toward fibre-based alternatives, particularly in molded fibre applications where brands are looking to replace traditional plastic packaging items. Chemistry plays a vital but often unseen role in this transformation.

Chemistry expertise provides properties that allow fibre-based packaging to compete with plastic – such as strength, hydrophobation, and barrier properties – but it also ensures production processes remain efficient and cost-effective. This ensures packaging solutions that are both compliant and commercially viable.

What else is Kemira doing to support

a wider transition into recyclable paper, and where is it going next?

Our commitment to paperization builds on decades of chemistry and application expertise in pulp and paper processes. The transition to functional, safe, and recyclable fibre-based packaging requires more than just innovative barrier coating solutions.

Our experience and know-how in the end-to-end process, from pulping to base paper production and coating to using recycled fibres, give us insight into developing comprehensive solutions throughout the packaging value chain. We’re strengthening this commitment further with our new organizational structure launching in January 2025, which includes a dedicated global Packaging and Hygiene business unit.

Creating high-performance, fibre-based packaging requires expertise across the entire production process. Our chemistry solutions enhance multiple aspects of packaging performance: strength additives ensure durability, hydrophobation provides water resistance, and microbiological control guarantees hygiene requirements are met.

We also focus on manufacturers’ operational efficiency – our solutions help optimize processes through effective deposit and foam control, while enabling efficient repulping and reuse of fibre material.

Looking ahead, our focus is on expanding our renewable product portfolio across applications and helping our customers optimize their production processes and quality through data-driven chemistry management and digital solutions.

CAN SERIALIZATION REALLY KEEP OUR PHARMACEUTICALS SAFE?

Serialization links a product to a database of information via a unique code; for over thirteen years, this technology has been compulsory for pharmaceutical packaging sold in Europe to help protect consumers from counterfeit medicine. But how accessible is it, and does it really work? Emma Liggins tells us more.

INpharmaceutical packaging, individual products are each assigned a unique serial number. The non-profit standards organization GS1 recommends that a batch number, expiration date, and Global Trade Item Number (GTIN) – i.e., an eight, twelve, thirteen, or fourteen-digit code – be displayed on the packaging for every pharmaceutical product.

The GTIN is implemented into a data matrix, such as a barcode, QR code, Radio Frequency Identification (RFID) tag, or Near-Field Communication (NFC) tag. The matrix is then printed onto a product’s packaging (if a pack is split into separate components, such as a bottle inside a box, their codes can be linked together). This process is called serialization.

At this point, a product becomes traceable. Its matrix is scanned as it travels through the supply chain, which can then be used to monitor the product’s

journey, pinpoint its current location, and verify on-pack information. This is not limited to individual products; a Serial Shipping Container Code (SSCC) can be linked to pallets, parcels, and other bulk deliveries, for example.

In theory, serialization nips the distribution of counterfeits in the bud. Any attempts to recirculate expired medication or slip falsified packaging into a product lot can be exposed, and their points of origin identified, before they fall into a patient’s hands. In turn, brands can build trust and loyalty among their consumer base – and, most importantly, keep them safe and healthy –by ensuring that every product sold in their name is genuine.

Matrixes alone do not account for counterfeiters targeting the product itself and evading detection by reassembling the original pack, but the EU’s Falsified Medicines Directive mandates a unique identifier and anti-

tampering device for any given pharmaceutical pack. This provides visual evidence of attempted interference, even if the GTIN reads as authentic.

Unfortunately, neither method is a catch-all. As recently as October 2024, the BBC identified over one hundred examples of consumers purchasing what they believed to be diazepam – only to end up taking nitazenes, or synthetic opioids that the National Crime Agency links to 278 deaths across the UK in a year. It suspects that such counterfeits are imported via everyday parcel operators like the Royal Mail and sold in deceptively realistic packaging.

Procedural shortcomings related to imports and illicit drug markets undoubtedly played a role here. Yet, when the World Health Organization

In theory, serialization nips the distribution of counterfeits in the bud. Any attempts to recirculate expired medication or slip falsified packaging into a product lot can be exposed, and their points of origin identified.

Where we are

Right now, the most common solutions are label serialization, in which a serialized code is applied to a sticker label, and in-line serialization, which prints the code directly onto a pack. Both processes take place at every stage of the supply chain.

A downside of these processes is that their traceability can be compromised. For example, a bulk delivery of pharmaceutical products may be unpackaged and portioned out to be sent to retailers. If the packaging is not handled with care, the codes may be damaged and require reapplication.

Unique identifiers themselves are not foolproof, either – most visible codes can be intentionally tampered with, removed, or even replicated, whether printed directly or labelled. In its article ‘What is serialization in pharma and

as reverse engineering such advanced technology will become too complex and expensive to be worthwhile. Invisible laser markings like hidden fingerprints and micro-holes are suggested as potential solutions.

Yet modifications to existing packaging lines, the installation of new software, and designing and printing new codes all require investments from manufacturers in an already expensive business. Atop lengthy drug development processes, clinical trials and studies, and financial losses associated with failed prototypes, small and medium-sized enterprises (SMEs) may struggle to upscale their technologies, especially if they lack the necessary automation to begin with.

Space is another necessity that SMEs may not have in abundance. If new machinery were the only way forward, progress may be limited to larger corporations with plenty of room on their factory floors.

Not every solution requires so much installation, though. Smithers forecasts that the global market for track and trace will increase at a 9.5% CAGR and exceed $2.5 billion by 2027, and attributes the rise in part to the continual development of blockchain technologies.

To grossly simplify, blockchain technology is an advanced database mechanism, sometimes described as a digital, decentralized ledger. Data is stored in a ‘block’, and blocks of encrypted data are linked in a ‘chain’. As such, any overwriting or alteration can be monitored, and ‘consensus mechanisms’ ensure that every device, or node, linked to the blockchain approves of an addition before it is made.

Blockchain technologies can usually be implemented into existing enterprise systems like EPR or MES, and while they may require upgrades in network infrastructure, cloud or edge computing power, and/or staff training protocols

– and, of course, to software – they do not always require modifications to production lines. Even if they do, they can unlock automated verification processes designed to catch counterfeits.

Matrixes can correspond with ‘smart contracts’ so that, when scanned, their data must match existing blockchain records of the product’s proof of origin, batch number, and expiry date to move forward. If a pack is not verified as authentic, it will not progress to the next stage of the supply chain.

Internet of Things (IoT) sensors can also be integrated into product packaging and connected to the blockchain. This solution picks up on suspicious activity, such as unusual changes in temperature, and triggers an automatic alert on the relevant system.

Old versus new

Some people uplift blockchain as the key to managing complex pharmaceutical supply chains, but researcher Cheman Shaik believes it to be an expensive and complicated solution for preventing counterfeit. Manufacturers must operate their own blockchains, he says, which puts the onus of managing nodes, backing up and recovering data and storage, managing confidentiality, and more onto just one organization.

In his paper, “Preventing Counterfeit Products Using Cryptography, QR Code and Webservice”, Shaik posits that manufacturers could instead insert a QR and unique item code into individual packs. Consumers would be encouraged to download a counterfeit detection app via a separate QR

code displayed on the manufacturer’s website, and then use it to scan their product’s in-pack QR code.

The user would subsequently be prompted to enter their item code into a text box. If this conflicted with the corresponding information in the manufacturer’s system, the app would flag the item as a counterfeit. Alternatively, a valid code would prompt the user to enter their name, with the app checking the two values against the manufacturer’s database and validating the product as genuine.

Right now, this solution is purely theoretical – and while it lifts the responsibility from manufacturers, it also relies on consumers a) owning both a smartphone and a computer, and b) having the technological prowess to navigate the internet and download apps. These factors may not apply to some elderly consumers, for example, whom the European Medicines Agency suggests are the ‘main users’ of medicines. This demographic may also suffer from visual impairments and struggle to copy a written item code.

Perhaps the simplest solution is already mandatory. On its own, an anti-tampering device can persuade a would-be counterfeiter by exposing a compromised pack; combined with serialization, it can provide physical and digital evidence of repeated security violations, enabling pharmaceutical companies to identify and address weak points in their supply chains.

On the other hand, it has the potential to cause inconvenience. Accidental mishandling in logistics, transit, or on the shop floor may damage the device, and although the possibility could encourage individuals to handle a pack

Even if there are still crinkles to iron out, it is undeniable that pharmaceutical packaging is safer with serialization codes than without them.

Meanwhile, anti-tampering devices are as susceptible to duplication as serial codes. If the design is simple and its material is accessible to consumers, the feature can be recreated; and increasing its complexity brings us back to rising costs for manufacturers.

An open and shut case?

This list of technologies isn’t exhaustive, but it reveals a running trend that serialization is fallible, not ineffective. It does combat counterfeiters, but not completely – and it requires support from other solutions and technologies, each of which comes with its own vulnerabilities.

Even if there are still crinkles to iron out, it is undeniable that pharmaceutical packaging is safer with serialization codes than without them. This is demonstrated by the likelihood of purchasing counterfeit products in highincome countries versus their low- or middle-income counterparts, and on legitimate markets versus illegally.

The Centers for Disease Control and Prevention state that less than 1% of medicines sold through retail in the United States are dupes, whereas the figure can range between 9% and 41% in less wealthy nations. Furthermore, many of the consumers affected by nitazenes in the BBC’s investigation had purchased drugs illegally, not over the counter.

The challenge now is to find ways to guarantee the success of serialization and ensure that every pharmaceutical company (and consumer) can access it at its best. Technologies must keep progressing to protect patients everywhere, not only in the most developed economies, and turn the falsification of medical treatments for profit into an exploit of the past.