UPM, Michelman and BOBST have introduced two new fibre-based packaging concepts designed to help brands respond to stricter European rules on single-use plastics, recyclability and material reduction. The solutions combine paper-based substrates, bio-based coatings and industrial coating technology, aiming to offer an easier route from development to large-scale production.

The concepts were presented at Interpack 2026 in Düsseldorf, where the companies highlighted how fibre-based packaging can be adopted without major changes to existing manufacturing lines. This is a key point for converters and brand owners, as many sustainable packaging alternatives fail to scale because they require new equipment, slower production speeds or complex process adjustments.

For the packaging industry, the next challenge is not only to create alternatives to plastic, but to make them industrially viable, recyclable and commercially competitive.

The initiative comes as European packaging legislation continues to move toward lower plastic dependency and higher recycling performance. Measures such as the Single-Use Plastics Directive have already changed expectations for food, beverage and retail packaging. At the same time, the broader regulatory direction in the EU is pushing companies to redesign packaging around circularity, waste prevention and improved end-of-life outcomes.

The first concept developed by the partners targets dry food applications such as tea bags, oatmeal packs and sugar stick packaging. These are product categories where flexible plastic or plastic-coated structures have traditionally been used to provide barrier performance and sealing reliability. The new concept uses fibre-based materials supported by bio-based coatings to provide protection while improving alignment with paper recycling expectations.

The second concept focuses on applications requiring stronger oxygen barrier performance, including cookies, chocolate and similar sensitive food products. In these segments, packaging must protect flavour, texture and shelf life while remaining efficient to process. According to the companies, the solution enables thinner coating layers, which can support material efficiency and reduce the overall environmental footprint of the pack.

Barrier performance remains one of the most important technical challenges in fibre-based packaging. Paper alone cannot always provide adequate resistance to moisture, oxygen, grease or mineral oils. Coatings therefore play a decisive role in determining whether a fibre-based structure can replace conventional plastic packaging. The partners state that their concepts offer protection against moisture, oxygen and mineral oils, as well as heat sealability across a broad temperature range.

• UPM contributes paper-based materials and fibre expertise.
• Michelman provides coating technologies designed to improve barrier and sealing properties.
• BOBST supports industrial coating and converting capabilities.
• Food brands gain potential alternatives for dry and oxygen-sensitive products.

For converters, the most relevant aspect may be compatibility with existing production infrastructure. Packaging innovation often faces a gap between laboratory success and factory reality. If a new material requires extensive equipment investment or disrupts line efficiency, adoption becomes slower. By designing concepts for implementation on current industrial lines, the companies are addressing one of the major barriers to market entry.

However, the shift from plastic to fibre-based packaging is not without complexity. Alternative materials can involve higher costs, limited raw material availability or different recycling requirements depending on local infrastructure. In some cases, replacing plastic can also affect shelf life, product protection or transport efficiency. This means that sustainability claims must be assessed through a full lifecycle perspective, not only by looking at the removal of plastic.

The development also reflects a broader movement in food packaging. Brands are under pressure from regulators, retailers and consumers to reduce visible plastic, but they still need reliable packaging that protects products and works at scale. Fibre-based formats are gaining attention because they are familiar to consumers, widely collected in many markets and able to support strong brand communication on shelf.

For the European packaging sector, solutions like these point to a future where paper, coatings and machinery must be developed together. A recyclable paper pack is not only a material choice; it is the result of coordinated design between substrate, coating chemistry, sealing performance, converting technology and end-of-life compatibility.

The new concepts from UPM, Michelman and BOBST show that fibre-based packaging is moving beyond pilot projects and into more practical industrial applications. As EU rules become stricter, companies that can combine regulatory compliance with performance and manufacturability will be better positioned to lead the next phase of sustainable food packaging.