Sustainable food packaging solutions: from concept to production

Sustainable food packaging is essential for the future, especially with the new PPWR requirements aligning with Europe’s waste rules, covering the entire packaging life cycle, from product design to waste management. We help replace hard-to-recycle multi-layer plastics with eco-friendly mono-material and paper solutions that comply with these evolving standards.

Primary packaging changes require precise sealing adjustments, and that’s our expertise. From concept to shelf, we analyze your needs, consult on responsible materials, test under real conditions, and develop, adapt, or retrofit your machines for optimal performance. In our test labs, we even produce samples so you can see and feel the quality.

Connect with an expert today to explore the best sustainable packaging solution for your needs.

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Paper

Our packaging machines can run both mono-material and cold- /heat-sealable barrier papers at high production efficiency.

Mono-material plastics

Innovative heat-sealing technology ensures a perfectly sealed closure for high product quality, even for very thin films.

Bioplastics

Our machines can efficiently package products in bioplastic films, allowing our customers to reduce their carbon footprint. Thanks to its biodegradability, the material helps to avoid plastic litter.

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Sustainability @Syntegon

What if food packaging could help preserve our planet? Let us challenge our view on conventional packaging – for a more sustainable world.

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Initial plunge towards sustainable packaging

In order to offer reliable, sustainable paper-based packaging solutions for large and medium-sized confectionery customers, we have entered into a strategic partnership with innovator Sappi Europe. While we normally pursue a packaging-material-independent approach and Sappi pursues a packaging-machine-independent approach, customers can now benefit from our combined expertise.

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Material Testing & Consulting

Learn more about our consulting services: we work with you to analyze your individual requirements for packaging materials, develop environmentally responsible packaging solutions and test them under conditions similar to those in your production.

Co-creating your solution

Together we analyze your individual requirements for packaging materials and test them under conditions similar to those in your production. Based on this comprehensive evaluation, you then receive individually tailored recommendations for sustainable materials.

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From material to machine – proven compatibility

Packaging materials can behave differently on various machines. Our machinability service tests your material in our labs, evaluating processing, sealing, speed, and quality to deliver a detailed report. We can also adapt or retrofit machines and provide packaging samples on request.

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Paper flow-wraps

There are numerous barrier papers available for different applications in the chocolate and bakery industry. We have already installed our retrofit kit "paper-ON-form" for numerous customers. It can be used for different types of barrier papers as well as for conventional packaging materials on the same machine, making it possible to switch materials on the fly. The forming unit and sealing jaws shape paper without creasing or tearing it. Our experts can pre-configure the unit and jaws for your desired pack size and specific material characteristics.

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Mono-material flow-wraps

Mono-material films consist of a single type of plastic, which makes them more temperature-sensitive. The extended stroke length for Amplified Heat Sealing (AHS) on our horizontal flow wrappers helps to optimize thermal heat input and enables faster processing. The precise application of heat to the film ensures tight packs.

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Horizontal packaging solutions: use case scenarios

Paper packaging for Balisto chocolate bars

We supported Mars Wrigley with investigating the flow wrapping potential of paper.

Optimal sealing quality for mono-material at high speeds

The extended hub length of the Amplified Heat Sealing technology allows extended sealing time, which is especially helpful for mono-material films.

Paper packaging for SMARTIES® tablets

With a retrofit for their existing machinery, we helped Nestlé UK switch to paper for their chocolate packaging.

Heat-seal paper for packaging cupcakes

Medium-speed heat-sealing application: The forming unit and sealing jaws are pre-configured for the desired pack size and material characteristics before being installed.

Paper packaging for Cadbury chocolate

Recently, Mondelēz International approached us with a challenging request: to package their Cadbury chocolate bars in recyclable paper flow wraps.

Cold-seal paper packaging for bars

High-speed cold-sealing application: The retrofit kit “paper-ON-form” for existing and new horizontal flow wrapping machines.

Interested?

Get in touch with us.

Paper bags

Syntegon vertical baggers can process paper to produce the most popular bag styles: pillow, gusseted, block-bottom, corner seal and Doy stand-up bags. Together with various material suppliers, we have developed proven technologies ensuring the ideal solution for your product. By applying sealing agent only selectively, we can achieve fiber content of up to 95 percent and help you move towards sustainable packaging. We also offer retrofits for an easy transition to paper packaging.

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Mono-material bags

Sustainability without compromises: our solutions maintain the high bag quality and production speed you know from conventional films. Vertical baggers from Syntegon can efficiently process mono-material films for the most popular bag styles: pillow, gusseted, block-bottom, corner seal and Doy stand-up bags including zip. In cooperation with various film suppliers, we have developed proven solutions, offering the right barrier properties for your product (up to a water vapor transmission rate of <1 and an oxygen transmission rate of < 1). New sealing systems can minimize the amount of film clamped during the sealing process, cutting film consumption by up to 6.8%.

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Vertical packaging solutions: use case scenarios

Ritter Sport minis in stand-up bags

Vertical baggers produce bend- and tear-resistant stand-up bags made of paper.

Pasta in sealed paper packaging

ALB-GOLD has begun selling its pasta in paper bags, which has been a great success with customers and retailers alike.

Frozen foods in BOPE pillow bags

Combination of our PHS 2.0 sealing technology and a 20-micrometer film from BOPE.

Wolf Nudeln in paper bags

With less than 5% sealing material content, the packaging counts as mono-material and can be recycled in the paper waste stream.

Paper stand-up pouch (Doy bag)

Our cooperation with Koehler enables customers to use paper on their existing machines to produce attractive bag shapes like Doy from paper.

High barrier meets recyclability

New PE-based flexible stand-up pouches with high barrier qualities offer toughness, stiffness and shelf appeal at high speeds on existing VFFS production lines.

Order your free set of sustainable bag samples

In the set you will find readily available packaging solutions.

Cartons

Our comprehensive portfolio of topload, endload and wraparound cartoners is designed for maximum efficiency. Our goals: maximum performance, minimum waste. Avoiding rejects not only saves costs, but also has a positive impact on the environment. Syntegon avoids adhesives in carton forming by using glue-free technologies such as ultrasonic sealing or our innovative lock-style technology – which has already replaced plastic trays in cookie packaging with paper trays. Both solutions provide viable, sustainable options for your secondary packaging processes.

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Cases

True to our sustainability mission, our case packing machines can process corrugated board made from renewable materials, such as grass fiber. Additionally, we are developing packaging solutions that reduce your material waste and overall costs. Our case packers are known for their efficient use of packaging materials, including the ability to work with bent blanks. From simple trays to shelf-ready trays with hoods, our case packers deliver maximum flexibility.

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Cartoning solutions: use case scenarios

Replacing plastic with paper trays?

Take a closer look at trays made from paper, which can replace commonly used plastic trays for cookies.

Cases made of grass fiber

Take a look at our case packer combined with a vertical bagger producing paper stand-up bags.

Sustainable carton packaging solutions

Customers can choose between glue, lock-style or innovative ultrasonic sealing technology.

Kliklok ACE – glue-free cartoning solutions

Thanks to our lock-style technology we can form cartons in a completely glue-free, environmentally friendly manner.

Our commitment to sustainability

By providing innovative technologies and future-proof systems, we help reduce emissions, waste, and resource use, while increasing operational efficiency. By fostering sustainable practices, Syntegon has a positive impact not only on the business of its customers but also on people and the planet.

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Packaging and sustainability downloads

Whitepaper: Practical advice on selecting the right material

Comparison of production processes and recyclability of sustainable packaging materials.

Sustainability Services Brochure

Our material testing and consulting services

Interested in sustainable packaging technology?

Reach out to our experts.

Do you want to make the switch to eco-friendly materials without compromising on efficiency or product quality? Do you have a specific project in mind? Get in touch with our experts!

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More Syntegon News

Sustainable food packaging solutions: from concept to production

Paper

Mono-material plastics

Bioplastics

Supporting you from the initial idea to the finished product on the shelf

Sustainability @Syntegon

Initial plunge towards sustainable packaging

Material Testing & Consulting

Accelerating your sustainability journey

Co-creating your solution

From material to machine – proven compatibility

Horizontal packaging solutions

Paper flow-wraps

Mono-material flow-wraps

Horizontal packaging solutions: use case scenarios

Paper packaging for Balisto chocolate bars

Optimal sealing quality for mono-material at high speeds

Paper packaging for SMARTIES® tablets

Heat-seal paper for packaging cupcakes

Paper packaging for Cadbury chocolate

Cold-seal paper packaging for bars

Interested?

Vertical packaging solutions

Paper bags

Mono-material bags

Vertical packaging solutions: use case scenarios

Ritter Sport minis in stand-up bags

Pasta in sealed paper packaging

Frozen foods in BOPE pillow bags

Wolf Nudeln in paper bags

Paper stand-up pouch (Doy bag)

High barrier meets recyclability

Order your free set of sustainable bag samples

Cartoning solutions​

Cartons

Cases

Cartoning solutions: use case scenarios

Replacing plastic with paper trays?

Cases made of grass fiber

Sustainable carton packaging solutions

Kliklok ACE – glue-free cartoning solutions

Our commitment to sustainability

Packaging and sustainability downloads

Whitepaper: Practical advice on selecting the right material

Sustainability Services Brochure

Interested in sustainable packaging technology?

Read our latest news

Cartoning solutions