Bosch Packaging Technology (boschpackaging.com) and BillerudKorsnäs developed the world´s first Sealed Paper Packaging. Instead of using polymer film, a new solution enables production of dust-tight packaging for dry products such as sugar, grains, flour or powders using sustainable mono-material paper, which contains no additional polymer fractions. As a result, retailers and consumers profit from clean shelves, high product protection and improved product quality. Swedish paper specialist BillerudKorsnäs contributed its expertise to the optimization of the mechanical properties of the paper, while Bosch Packaging Technology proved its competence as a leading provider of packaging technology.

The paper packaging is produced on the first vertical form, fill and seal machine (VFFS) with the so-called ZAP-Module. The module allows coating with the sealing agent on a minimal surface area, preserving the paper`s mono-material character. The solution is based on the proven PME machine concept from Bosch. The new solution combines this technology with the Axello®ZAP paper from BillerudKorsnäs.

“This revolutionary concept would not have been implemented without the collaborative effort of both companies. Together we have developed a solution that will change the packaging market,” says Joachim Dittrich, head of Liquid Food product division at Bosch Packaging Technology, responsible for the VFFS ZAP portfolio.

Great offer for environmentally conscious consumers. Compared to conventional paper, AxelloZAP is substantially more durable, while retaining its natural paper characteristics and advantages from source to recycling. The sustainable characteristics of the material increase its appeal to eco-conscious consumers. With the AxelloZAP paper, BillerudKorsnäs has developed a new, better packaging material which reliably withstands the stronger mechanical requirements in processing.

“The combination of the strength, flexibility and stiffness of AxelloZAP paper fits perfectly with Bosch’s technology,” says Ole Paulussen, sales director at BillerudKorsnäs.

More flexibility for formats and pack styles. Until now, the production of mono-material paper packaging was only possible with glued pre-made bags or formed paper bags on mandrel wheel technology. The VFFS concept, more flexible regarding formats and pack styles and thus popular on the market, so far only allowed bag production using polymer film or fully coated paper. With the ZAP-Module from Bosch it is now possible to process mono-material paper on VFFS technology with dust-tight sealing. The secret lies in the characteristics of the AxelloZAP paper, which was specially developed for this application, as well as in the ZAP-Module, which applies a minimal amount of the sealing agent during the packaging process to enable heatsealing of the paper on the VFFS machine.

Revolution in the dry food market. The solution meets the growing demand for sustainable packaging for dry foods such as sugar, flour, grains and powders. Moreover, the machine is user-friendly and allows versatile packaging styles, including pillow, gusseted and block bottom bags with gable or flat top closure. “We are positive that our solution, supported by several years of development, not only addresses today’s challenges for our customers but also gives them the possibility to enter completely new markets and areas of application using sustainable packaging,” said Marcus Velezmoro, sales responsible for the VFFS ZAP portfolio at Bosch Packaging Technology.