Stahl targets recyclable metallic decoration for paper packaging

Stahl has launched Senoprint, a new portfolio of metallic coatings designed to deliver high-impact silver and gold finishes on paper and board packaging while maintaining compatibility with conventional recycling processes.

The coatings are positioned as an alternative to traditional hot foil stamping and cold foil applications, allowing metallic effects to be created directly during the printing process.

According to Stahl, the technology can simplify production, reduce material use and support packaging designs aligned with the recyclability requirements of the EU Packaging and Packaging Waste Regulation.

Metallic effects are applied directly during printing

Traditional foil decoration typically requires a separate application step and additional metallic material to be laminated or transferred onto the packaging surface.

Senoprint instead creates a reflective metallic finish using a printable coating, allowing converters to integrate decoration into existing printing workflows.

The portfolio is suitable for flexographic, screen, sheetfed and narrow-web applications across paper and board substrates.

Coatings are designed for de-inking and fibre recovery

A key feature of the technology is its compatibility with standard paper recycling processes.

Stahl says the metallic layer can be removed during de-inking, allowing the underlying fibres to be recovered without the complications that can arise from separate foil layers.

This is becoming increasingly important as packaging designers seek decorative effects that do not compromise the recyclability of the complete pack.

Water-based and UV formulations support different applications

The Senoprint range is available in both water-based and UV-curable formulations, giving converters flexibility according to printing technology, substrate and production requirements.

The company says the water-based options can also support lower-VOC packaging applications, while UV versions offer the fast curing performance required in high-speed converting environments.

The current portfolio includes silver and gold finishes, with additional metallic shades achievable through overprinting.

Protective topcoat preserves brilliance and durability

Each metallic coating is combined with a protective topcoat developed by Stahl as part of an integrated system.

The topcoat is designed to maintain the visual brilliance of the metallic finish while improving resistance to abrasion, handling and environmental exposure.

This durability is particularly relevant for premium packaging and labels, where decorative surfaces must remain visually consistent throughout filling, transport and retail handling.

Premium packaging seeks alternatives to conventional foil

Metallic decoration remains widely used across luxury, cosmetics, spirits, confectionery and other premium packaging categories because of its ability to create strong shelf impact.

However, conventional foil structures can introduce additional materials and production steps that complicate recyclability assessments.

Printable metallic coatings offer a potential route to retain the visual qualities associated with foil while simplifying the material structure of paper-based packaging.

PPWR increases pressure on decorative packaging components

As the PPWR moves packaging design towards greater recyclability, decorative elements are increasingly being assessed not only for appearance but also for their impact on sorting, de-inking and fibre recovery.

This creates pressure on converters and brand owners to reconsider coatings, laminates, foils and other secondary materials that can affect recycling performance.

With Senoprint, Stahl is positioning metallic decoration as a functional part of recyclable packaging design rather than as an additional layer that must be managed separately at end of life.