CAN BARRIER PAPER REPLACE PLASTIC?

Barrier paper is not merely a change of material, but a technological leap in quality. Depending on their structure, modern paper packaging solutions can combine protection against oxygen, moisture, water vapour, grease and oil with printability and sealability.

A fair comparison is therefore not simply a matter of ‘old versus new’ or ‘plastic versus paper’. A new packaging solution must be assessed on the basis of its overall performance profile. This includes product protection, processability, recyclability, brand impact and the costs across the entire value chain.

It is precisely this holistic approach that lays the foundation for a sustainable decision.

Brand owners are looking for packaging that combines product protection, brand impact and a credible circular economy approach. At the same time, the Packaging and Packaging Waste Regulation (PPWR) is raising the bar in terms of packaging design, compliance, labelling and recyclability. The Regulation came into force on 11 February 2025 and has generally applied since 12 August 2026. 

This makes barrier paper an attractive option for the further development of packaging. Modern paper packaging can fulfil demanding functions in suitable applications. The key lies in a precisely engineered barrier system that integrates material, coating, product protection, the manufacturing process and recyclability.
 

Barrier paper is a paper-based packaging material whose fibre base is supplemented by functional coatings or additional layers. These layers are designed to protect the product from certain external influences whilst also enabling it to be processed into packaging material.

This means that barrier paper is not standard uncoated paper. It is a carefully engineered material composition. The paper base provides the fibre content, texture and printability. Functional layers add properties required for product protection, sealability or processing on packaging machinery.

Felix Schoeller offers various material systems with paper content ranging from around 80 to 95 per cent. These figures depend on the specific product and application. They do not represent a blanket statement for every type of barrier paper and are no substitute for testing the specific structure of the packaging material.

The key question is therefore not simply: How much paper does the packaging contain? What matters is: Does the entire system fulfil the necessary function, does it perform reliably, and is its recycling pathway traceable?
 

Depending on the paper base, coating technology and layer structure, modern barrier papers can combine different functions.

Actual performance always depends on the specific application. A material suitable for dry powdered food is not necessarily the right solution for a fatty or frozen product. Further details on the paper’s properties can be found on the respective product pages.
 

Various technologies can be used in the development of functional paper packaging. These include, amongst others, extrusion coating, curtain coating and dispersion coating.

In extrusion coating, a thin polymer layer is applied to a substrate, providing barriers against oxygen, grease, MOSH and MOAH, as well as moisture. Sealability and a flexible, tear-resistant coating are also options.

Dispersion coating using the curtain coating process enables contact-free application and a uniform film thickness. The technology can be used for multi-layer systems and the precise design of functional properties. 

Furthermore, other coatings, such as lacquers, can be applied using a printing process. 

The choice of technology depends on the application. Therefore, a robust development process does not begin with the selection of a standard product, but with the definition of the required functions.
 

More sustainable packaging should not be assessed solely on the basis of whether it costs less than the current material price. If a solution combines a high level of product protection with a higher proportion of paper, traceable recyclability, a high-quality feel and reliable processing, its functional and qualitative value also increases.

This does not mean that barrier paper is automatically the better or cheaper solution in every application. It means that the comparison must reflect the packaging’s overall performance. The key criteria are product protection, barrier properties, sealability, machine runnability, recyclability, brand impact and scalability.

Barrier paper can therefore set a new standard for packaging. Price is one factor in the decision, but not the sole criterion.

Paper-based solutions are particularly attractive in situations where brand manufacturers wish to reduce the proportion of plastic or reassess existing composite structures. Possible areas of application include:

• dry foods such as rice, pasta, pulses and powders
• snacks
• confectionery
• Baking mixes and other bakery applications
• butter
• Ice cream and selected frozen food applications
• Dishwasher tablets
• Seeds
• Pet food

Suitability must be assessed in each individual case. Applications with very high requirements for liquid resistance, mechanical strength, absolute leak-tightness or a long shelf life under difficult conditions require particular attention.

Barrier paper is therefore not a universal substitute for all plastic or composite packaging. Liquids, beverages and industrial chemicals are not among the prioritised areas of application in this packaging context. Responsible advice must clearly identify such limitations.
 

In a specific application, paper may be more expensive than a previous plastic solution. However, the decisive factor is not the price of the material per kilogramme, but the value of the overall solution: packaging that fulfils functional barrier requirements, is more easily recyclable and supports brand requirements offers greater performance and sustainability. This added value must be taken into account in the assessment.

A realistic assessment considers three aspects:

1. Material and function: What levels of barrier performance, sealability, tactile feel and printability are achieved?
2. Process and quality: How stable is the packaging in operation, what is the validation effort involved, and how well can it be scaled up?
3. Circularity and brand value: How recyclable is the specific design, what regulatory prospects does it offer, and how does it contribute to brand positioning?

The price may change as standards rise. It is crucial that the added value is made transparent and that the packaging is assessed as a complete solution. This also includes product protection, security of supply, disposal, documentation and the avoidance of unnecessary risks along the value chain.
 

Brand manufacturers are advised to assess both the existing and the new packaging against the same product protection requirements, shelf life and production volume. In addition, recyclability, material composition, machine performance, waste, development costs and brand impact should be taken into account.

This will reveal whether the new solution not only uses a different material but also establishes a higher and more sustainable packaging standard.
 

Recyclability is a property of the packaging as a whole, not just the paper base. Coatings, printing inks, adhesives and other layers, as well as collection and recycling routes, must be considered together. A high paper content is relevant, but is not in itself proof of recyclability. Conversely, a coating is not automatically a criterion for exclusion.

The European guidelines for paper-based packaging recommend that functionality and end-of-life considerations be integrated from the design phase onwards. 

The PPWR reinforces this life-cycle perspective. It covers, amongst other things, packaging design, compliance, labelling and recyclability. It is therefore worthwhile for brand owners to incorporate material selection, packaging structure and supporting documentation into the development process at an early stage. The PPWR does not automatically favour paper. Rather, it emphasises the importance of a traceable, sustainable packaging solution.  

At Felix Schoeller, our motto is: “We diagnose before we design”. This means we listen, analyse and design together. The development process therefore begins with a reality check. Together with the customer, we consider the following points, amongst others:

1. Product, application and shelf-life requirements
2. Required barriers and product protection
3. Existing materials and packaging structures
4. Machinery, processes and sealing conditions
5. Print appearance, tactile feel and branding requirements
6. Recycling pathway and required evidence
7. Supply chain, availability and scalability
8. Costs, risks and regulatory requirements

Only then does the design of the solution follow, involving the selection of suitable materials, barriers and coating technologies. The solution is validated through samples, prototyping and machine trials.

It is crucial that a material performs well not only on paper but also in real-world applications. This includes consistent quality, reliable processing, adequate product protection and the ability to scale the solution to industrially relevant quantities.
 

Felix Schoeller combines several areas of expertise that are relevant to brand manufacturers undergoing packaging transformation:

• Material engineering: The material composition is tailored to the product and process.
• Coating technology: Extrusion, curtain coating and dispersion offer a range of solutions.
• Co-creation: Brand owners, converters, packagers and other partners are involved throughout the value chain.
• Prototyping and machine trials: Technical and economic risks are identified before scaling up.
• Circularity: Recyclability is considered as part of product development.
• Tactile feel and printability: Product protection and brand impact are assessed jointly.
• Agile development: Small batch sizes and rapid learning cycles can support the validation of new solutions.

Felix Schoeller does not see itself merely as a standard supplier. Its aim is to work with customers and partners to develop the solution that best suits the product, process, brand and recycling target.

This practical approach is crucial for branded goods manufacturers. Daniel Zimmermann, Head of Sales & New Business Development at Felix Schoeller, sums it up in the context of developing new packaging solutions: 

“A barrier paper is not the right solution simply because it has a high paper content. What matters is whether it meets the product’s requirements, runs reliably on the intended machine and fits into a traceable recycling pathway. These are precisely the points we examine together with our customers before we scale up a solution.”
 

Can barrier paper replace plastic? In many applications, the answer is: yes, provided that paper is seen as part of a precisely engineered barrier system.

Modern paper packaging can combine product protection, a high-quality feel and recyclability. Its value is therefore not determined by the price of the material alone. As packaging standards rise, the price may also change. What matters is the overall performance – from the barrier properties and processing to recyclability and brand impact.

At Felix Schoeller, we support brand owners and partners in developing and validating this performance for their specific application. In this way, the idea of paper packaging becomes a solution that delivers on technical, economic and sustainability fronts.

Are you assessing whether paper-based packaging is suitable for your application? Start with a reality check. Together, we’ll examine your product and barrier requirements, production processes, brand requirements, recycling targets and cost-effectiveness before developing the right solution.
 

1. European Commission: Packaging and Packaging Waste Regulation, accessed in September 2026
2. European Commission: Packaging waste, accessed in September 2026
3. CEPI: Guidelines on the recyclability of paper-based packaging, accessed in September 2026