Koehler Paper is expanding its development of fibre-based flexible packaging as brands, converters and retailers seek alternatives that combine product protection with recyclability and lower material use.

Alexander Rauer, Head of Business Development Flexible Packaging Paper at Koehler Paper, says circularity increasingly needs to be considered at the packaging design stage rather than addressed only after a product reaches the waste stream.

“Circularity starts with design,” Rauer said. “The most sustainable packaging solution is one that not only protects the product but also fits seamlessly into existing recycling systems.”

The approach forms part of the wider Koehler Group target for 100% of its innovations to meet relevant sustainability criteria by 2030.

Sustainability Becomes a Packaging Design Requirement

For Koehler Paper, the target means sustainability is being incorporated directly into the development of new packaging products.

Flexible packaging presents a particular opportunity because it generally uses less material than rigid packaging for comparable applications.

When fibre-based structures are used, another potential advantage is access to established paper collection and recycling systems. This can allow recovered fibres to remain in circulation rather than relying on entirely new end-of-life infrastructure.

However, Rauer stressed that sustainability cannot come at the expense of the packaging’s primary functions.

Brand owners and converters still require appropriate product protection, machinability and other performance characteristics alongside recyclability.

NexFlex Targets Different Flexible Packaging Requirements

At the centre of Koehler Paper’s flexible packaging strategy is the Koehler NexFlex portfolio.

The product family is divided into three main groups.

Koehler NexPure consists of uncoated machine-glazed papers designed for applications including confectionery wraps, tea packaging and other primary packaging formats.

Koehler NexCoat provides a one-side-coated paper developed for printability and converting performance.

Koehler NexPlus adds functional barrier properties. Depending on the application, these can include heat sealability and barriers against oxygen, grease, water vapour, aroma and UV, as well as MOSH/MOAH protection.

The modular approach allows barrier performance to be adapted to individual packaging requirements.

Potential applications include cereals, confectionery, snacks, bakery products, tea, fast-moving consumer goods and selected non-food products.

Koehler says the papers are designed for processing on conventional converting and packaging equipment while supporting recycling through existing paper streams.

Collaboration Extends Across the Packaging Value Chain

Moving from plastic to fibre-based flexible packaging is not solely a paper-development challenge.

Material suppliers, converters, packaging machinery manufacturers and brand owners all influence whether a new structure can operate successfully at commercial scale.

Koehler points to its work with Italian confectionery manufacturer Loacker as one example. The collaboration has examined the packaging lifecycle beyond product consumption and into the paper recycling process.

The company is also involved in development projects with other brands and converters seeking to replace conventional plastic structures with recyclable paper-based alternatives.

At an industry level, Koehler participates in 4evergreen, the European alliance focused on improving the circularity of fibre-based packaging.

Recycling Infrastructure Influences Material Development

Existing waste infrastructure is an important consideration in Koehler’s approach.

A packaging material may offer favourable environmental characteristics, but practical circularity also depends on whether it can enter established collection, sorting and recycling systems.

This makes compatibility with existing paper recycling infrastructure a design criterion rather than an issue considered only after development.

European regulation is reinforcing this approach.

The EU Packaging and Packaging Waste Regulation (PPWR) is increasing attention on packaging recyclability and other environmental performance requirements, influencing decisions by brands and packaging suppliers.

Rauer said customers are increasingly examining recyclability, future regulatory compliance and the potential implications of Extended Producer Responsibility costs when selecting packaging materials.

Paper Cannot Replace Plastic in Every Application

Despite the growing interest in fibre-based alternatives, Koehler does not suggest that every flexible plastic package can immediately be converted to paper.

Different products require different levels of moisture, oxygen, grease and aroma protection. Shelf-life requirements, packaging machinery and economics can also determine whether a material transition is practical.

The company’s approach is therefore to target applications where replacing plastic with paper is technically and economically feasible.

This distinction becomes particularly important for high-barrier applications, where reducing non-fibre components while maintaining adequate product protection remains a significant development challenge.

Koehler Plans Further Barrier Paper Development

Koehler Paper intends to continue expanding its NexFlex portfolio as demand for recyclable flexible packaging develops.

Future work will focus on improving barrier performance, extending the range of potential applications and developing products that respond to changing regulatory requirements.

The direction reflects a wider shift in packaging development: material performance is increasingly being assessed alongside what happens to the package after use.

For fibre-based flexible packaging, the opportunity lies not simply in replacing plastic, but in designing structures that can provide the required packaging performance while fitting into established recycling systems.

Last Updated on 18/08/2026 by Jota Machinery