Bobst, Brückner Maschinenbau partners to unveil recyclable monomaterial retort packaging

GERMANY – Bobst and Brückner Maschinenbau, equipment makers in partnership with chemicals firm Mitsui Chemicals, introduced what they describe as the world’s first monomaterial metallized retort solution. 

The innovation targets high-barrier pouches for sterilized foods, enabling them to enter standard recycling streams without the need for multi-layer composites.

The innovation addresses longstanding issues in retort packaging, where high temperatures during sterilization often degrade barrier performance. 

The new system relies on polypropylene film enhanced by an ultra-thin, heat-resistant primer from Mitsui, inline coating from Brückner, and Bobst’s vacuum metallization process. 

According to project leads, the result delivers opaque metallization that withstands retort conditions while maintaining protection against oxygen and moisture.

Willi Lindemann, a specialist in inline coating and new technologies at Brückner, highlighted the progress during a presentation. 

“We have reached a significant milestone, but development continues to ensure commercial viability,” he said. 

Lindemann noted that the technology suits a range of sterilized products, including wet pet food, and could soon involve additional partners for scalability.

Brückner’s extrusion and orientation expertise for thin layers, Mitsui’s primer formulation to prevent corrosion from heat-induced water vapor, and Bobst’s AluBond metallizer for improved adhesion and long-term surface energy. 

Reels produced on Brückner’s German pilot line underwent metallization at Bobst’s UK facility, where testing confirmed the material’s integrity post-retort.

Nick Copeland, Bobst’s R&D director for barrier solutions, explained the technical synergy in a statement. 

“The ultra-thin coating paired with precise metallization achieves superior barrier levels,” he said. 

He added that on-site experts in Manchester validated the material’s performance, overcoming shrinkage risks inherent in monomaterial shifts from traditional polyester-aluminum setups.

Anrika Heermant, a senior specialist at Mitsui Chemicals Europe, pointed to the retort process’s demands as the core hurdle. 

High temperatures previously caused barrier failure in metallized films, she noted, but the new primer ensures durability. 

This announcement comes amid heightened focus on circular economy goals, with K 2025 featuring over 50 sustainability-focused exhibits. 

The retort solution joins a wave of mono-material advancements, such as recent pilots for coffee pouches, showing accelerated industry shifts toward recyclable formats.

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