Why is Koehler NexPlus® flexible packaging paper the right choice?

The Packaging and Packaging Waste Regulation (PPWR) entered into force by the European Commission on 11 February 2025. It has changed already the market for flexible packaging in the EU and the rest of the world. The PPWR aims to reduce packaging waste, promote resource efficiency and transition towards a circular economy. However, this new regulation came with difficult interpretation and the industry is facing a lack of clarity.

Why are Koehler NexPlus® flexible packaging paper solutions the option of choice for converters, packers and brand owners around the world? Can they help to be compliant with the PPWR? Below we compare two types of pasta packaging. How do they perform in terms of waste disposal, recyclability and plastic content? This example illustrates the advantage of Koehler NexPlus® paper.

The composition of the packaging 

To illustrate this topic, we compare two different types of packaging that are both in the market:

• Packaging 1: Bag of pasta with material composition of a kraft machine glazed base paper with grammage of 60 gsm coextruded with polypropylene with a thickness of 30 micron (27,3gsm), total material weight: 87,3gsm.
• Packaging 2: Bag of pasta from the brand Iris with material composition of Koehler NexPlus® Seal Pure in grammage of 80 gsm. The dispersion coating that provides the sealing function is water-based with a coating weight of 4 gsm. The dispersion coating is applied on a paper coating machine.

Recycling codes

The first packaging is labeled with the recycling code C/PAP 81, a recycling code for composite packaging with the primary material being paper. In this application it is combined with extruded polypropylene. The second packaging of Koehler NexPlus® Seal Pure 80 is considered PAP 22 (paper), specifically indicating that the material is paper and can be recycled with books, and newspapers.

It depends on the country or municipality which waste stream the consumer will need to dispose the packaging. Rules differ across Europe and globally, also different EPR (Extended Producer Responsibility) fees may apply.

Recyclability

Let’s assume both pasta bags land in the paper recycling stream. The difference in their recyclability is substantial. 

The PPWR required all packaging placed on the EU market to be recyclable by 2030. A minimum recyclability level of 70% is set as for packaging to be considered designed for recycling (DfR). Final definitions what qualifies as recyclable packaging or not, will only be finalized in 2028. However, everyone placing packaging on the market should prepare and plan to migrate to recyclable packaging solutions.

For paper, CEPI (the Confederation of European Paper Industries) together with 4Evergreen, a cross-industry alliance of over 100 members representing the entire lifecycle of fiber-based packaging, have been developing a Recyclability Testing Method for standard paper recycling mills processes: The CEPI Recyclability Evaluation Protocol (Part I Recycling mill with conventional process). This method results in a score which depends on a whole list of parameters. Screening yield, sheet adhesion, dissolved and colloidal substances and visual impurities. 

As DCS (Dissolved and Colloidal Substances) is not relevant in the case of these materials, the total screening yield assessed according to the CEPI protocol can be used to grade the material according to the recyclability performance grades of the PPWR:

The TSR (Total Screening reject) and TSY (Total Screening Yield) of each packaging are asse. The calculation is shown below and more details can be found in this document. 

The recyclability performance grades according to table 3 of the PPWR:

Koehler NexPlus® Seal Pure: Grade B as of 2030 and also after 2038

The pasta bag consisting of a composite material ‘Packaging 1’ has a TSY of 63,7 %, by the CEPI standard and is not considered as recyclable. It has a high chance of not being compliant with PPWR requirements and then could not be placed onto the EU market as of 2030.

The pasta bag made with the Koehler NexPlus® Seal fexible packaging paper ‘Packaging 2’ has a TSY of 92,8 % being considered as recyclable in a recycling mill with conventional process. At that recyclability rate it remains with PPWR and in the current state of the legislation graded as B in DfR criteria.

Reduction of plastic content 

The PPWR aims to reduce plastic packaging and waste through various measures. Key aspects include reducing the overall packaging volume. The PPWR mandates a reduction in packaging per capita by 5% by 2030, 10% by 2035, and 15% by 2040, relative to 2018 levels.

Below are two pictures of the coarse reject in percent of the packaging that influences the TSY. Coarse reject is defined as weight percent of packaging removed by coarse screening and dry removed components. It is evident the lower amount of plastic in the NexPlus® Seal Pure 80 gsm paper (packaging 2) which has a CR rate of 6,8 % while the packaging 1 of 36 %.

In case we use this example and we assume 300 tons of packaging is used for a brand to pack pasta. In case we use Koehler NexPlus® Seal Pure 80 as the alternative material the reduction of plastic consumption compared to the composite packaging is around 85 tons per annum. For 10 years, the reduction will be 850 tons of plastic. It is a significant reduction in fossil-based material waste aligned with PPWR goals proving that as sooner this regulation comes into market, the better for the environment.

Conclusion

The comparison above gives an overview of how a Koehler NexPlus® paper grade can be a future proof option for converters, packers and brands to comply with the PPWR . 

The recyclability of paper is mature, and its infrastructure is available on a large scale. Iris already benefits with NexPlus® paper packaging. There is no time to waste.