Sappi expands barrier paper portfolio to meet growing packaging demands

EUROPE – Sappi has expanded its barrier paper portfolio for flexible packaging applications, as demand accelerates for fibre-based alternatives that can replace plastics without disrupting existing production lines.

The move strengthens the company’s offering of mono-material papers designed to run on conventional packaging equipment while qualifying for established paper recycling streams.

The paper and pulp manufacturer has been developing barrier papers for more than a decade, leveraging dispersion-based technologies that provide moisture and oxygen protection while remaining recyclable in standard paper waste streams.

The portfolio targets a wide range of dry and semi-dry food applications, including tea, cereals, chocolate, flour, dried fruits and nuts, instant soups and sugar.

“Brand owners want alternatives to plastic that fit into their real production environment,” said Gustavo Duarte, head of business development at Sappi Europe.

“Interest has grown fast in recent years. Customers need materials that actually solve their problems, not just ideas that sound good in theory.”

Sappi’s barrier papers are engineered around three core requirements: effective product protection, compatibility with existing packaging machinery and recyclability.

While the materials typically require adjustments to tension, heat and sealing pressure, the company says most customers can avoid investing in entirely new production lines.

“Paper needs a different kind of care and attention than plastic films,” explained Alexander Schröder, product application leader at Sappi.

“But this doesn’t mean customers need new lines. Often it comes down to fine-tuning. We work closely with machine manufacturers to help customers understand what needs to be adjusted before they switch.”

To de-risk adoption, Sappi tests its materials using CEPI and 4evergreen protocols before seeking external certification.

This approach is intended to identify recyclability or performance issues early and ensure alignment with the EU’s upcoming Packaging and Packaging Waste Regulation (PPWR).

“This early testing helps us refine the papers quickly and gives customers confidence that the material will meet not just today’s rules, but tomorrow’s as well,” Duarte added.

Sustainability credentials remain central to the company’s strategy. Sappi sources wood within approximately 150 kilometres of each European mill and maintains FSC, PEFC and SFI certification across its global supply chain.

It also manages around 400,000 hectares of certified plantations in South Africa, supplying local markets exclusively.

Although barrier papers can appear more expensive than some plastic alternatives, Sappi argues that total cost comparisons increasingly favour paper when recycling fees, regulatory costs and incentives for recyclable materials are factored in.

The expansion follows Sappi’s inclusion on the 2025 CDP A-List for Forests, earning an ‘A’ score among nearly 20,000 companies assessed by the Carbon Disclosure Project.

The company also reported strong ratings for Climate Change (A-) and Water Security (B), underscoring its broader push toward environmental resilience and transparency as brand owners prepare for tighter sustainability and compliance requirements across Europe.

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