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Fibre-based barrier papers

Questions and Answers

The switch from plastic to paper packaging raises many questions.

Here you can find out how barrier papers work, what applications are possible and how we can work with you to develop a suitable packaging solution.

Technology & Accessibility Features

  • What is barrier paper and how does it work?

    Barrier paper is a specialised type of paper which, through targeted coatings, is given functional protective barriers against moisture, oxygen, fats, mineral oils or flavours. The substrate is paper or board; the barrier effect is created by one or more thin coating layers on the surface. Unlike conventional paper, barrier paper can therefore perform tasks that were previously the preserve of plastic films or aluminium, such as protecting food from drying out, oxidation or rancidity.

     

    Our Felix Schoeller approach: We combine in-depth substrate expertise with advanced coating technologies to develop bespoke barrier systems that are precisely tailored to your application.

  • What is curtain coating, and what are the benefits of this technology?

    Curtain coating is a coating process in which an even ‘curtain’ of liquid coating material is applied directly to the substrate. The paper passes beneath the curtain; the curtain of coating material is applied directly to the substrate without the use of aids such as printing cylinders or an anilox roller, which is particularly gentle on sensitive substrates.

     

    Advantages at a glance:

    • Extremely uniform film thickness, even with very thin application layers
    • Industrial scalability at high speeds
    • Multi-layer coatings possible in a single pass
    • Minimal material loss due to contactless application
    • Suitable for water-based, solvent-free formulations


    Felix Schoeller USP: The industrial scaling of curtain coating technology is a key strategic objective. We are one of the few suppliers to utilise and further develop this technology for barrier papers on an industrial scale.  

    “Curtain coating is not simply another coating process. It is a paradigm shift. The precision with which we can apply barrier layers opens up possibilities that are simply unattainable with traditional methods. That is precisely what makes the difference between a barrier paper that delivers good data and one that truly impresses in practice.”  

    - Andreas Bergmeier, Head of Innovation & Technical Sales Packaging

  • What barrier properties can be achieved with barrier papers?

    Depending on the coating system and substrate, modern barrier papers can achieve the following barrier properties:

    • Moisture barrier (WVTR): Protection against water vapour transmission – relevant for dry products such as powders, rice, pasta or baking mixes
    • Oxygen barrier (OTR): Extended shelf life through protection against oxidation – important for snacks, confectionery and coffee
    • Mineral oil barrier (MOSH/MOAH): protection against the migration of mineral oils from recycled paper or printing inks
    • Aroma barrier: Preservation of product aromas and protection against foreign
        odours

    Important to note: Not every combination of barrier properties can be achieved with a single type of paper. We’ll work with you to determine which barrier values are realistic for your application during a joint ‘reality check’.

  • Are barrier papers machine-compatible and can they be processed on existing packaging lines?

    Machine compatibility is one of the key challenges when switching from plastic to paper. Paper behaves differently mechanically to film: it is stiffer, less stretchy and reacts to moisture and temperature. In practice, this means that whilst many existing packaging lines can process barrier papers, adjustments to machine parameters (tension, temperature, sealing conditions) are sometimes helpful and set a new standard. In specific cases, retrofits or new sealing tools are the best course of action.

     

    Our approach: machine compatibility is an integral part of our solution design process. We analyse your existing lines and develop solutions tailored to your machines, including machine trials and validation prior to series production.

  • How long does it take to develop a bespoke barrier paper?

    If none of our standard solutions are suitable, the development time will depend on the complexity of the requirements. As a rough guide:

    • Simple adaptations of existing solutions: 4–8 weeks until the first prototype
    • Specialised barrier systems with specific requirements: 3–9 months (prototyping, machine testing, validation)
    • Complex multi-barrier solutions with certification requirements and storage tests: 9–18 months until production readiness


    Our agile development approach enables rapid prototyping and iterative adjustments. This allows us to reduce development cycles and bring solutions into series production more quickly.

Sustainability & Recyclability

  • Is barrier paper really recyclable, or is that just a marketing claim?

    Whether a barrier paper can be recycled within the paper cycle depends on the specific coating structure and the conditions of the relevant waste paper processing. Tests in accordance with the CEPI 4EverGreen Method 3 are available for certain barrier solutions. 

     

    Please note: The results relate to the specific product variant tested and the test conditions defined therein. Actual recycling may also depend on the local collection, sorting and recycling infrastructure in the end product’s target market.

     

    “For us, credible recyclability begins with concrete evidence: for each product variant tested, we document the results in accordance with the test method applied, including the underlying test conditions. This creates transparency and provides a robust basis for decision-making. Whether a paper is actually recycled also depends on the local collection, sorting and recycling infrastructure.” 

    - Dr Maximilian Deutsch, R&I Project Manager, Coating Development Barrier

  • What test methods and evidence are available to demonstrate recyclability?

    There are various test methods and assessment frameworks for evaluating the recyclability of paper packaging. Depending on the method, these examine, for example, defibreability, the separability of components, de-inkability or the behaviour of a material in a defined paper recycling process.

     

    It is important to note that not every test constitutes certification. A test report or assessment always refers to the specific product variant tested, the method used and the underlying test conditions.

     

    The methods and assessment frameworks used in Europe include, for example:

    • PTS-RH 021/97: Testing of specific properties of paper and board products under defined conditions, particularly with regard to their defibrability or repulpability.
    • INGEDE methods: Methods for assessing individual recycling parameters, including de-inkability. They do not automatically equate to a comprehensive certificate of general recyclability.
    • CEPI Recyclability Test Method: A laboratory procedure for investigating technical recyclability within a defined recycling process. The method can serve as a basis for further assessments. cepi
    • 4evergreen Recyclability Evaluation Protocol: An evaluation protocol for fibre-based packaging that systematically classifies test results and takes different recycling processes into account. 4evergreenforum

    Technical tests are carried out
    on selected barrier solutions from Felix Schoeller by suitable testing institutes. The results relate in each case to the tested product variant, the method used and the defined test conditions. Depending on the product, the relevant documentation may include, for example, details of the test procedure, the testing institute, the result and the scope of application.

     

    A technical test demonstrates how a material behaves under the specified conditions. Whether it is actually recycled also depends on the local collection, sorting and recycling infrastructure, which may vary from market to market. cepi

  • How does barrier paper compare to plastic packaging in terms of its carbon footprint?

    A general comparison between barrier paper and plastic packaging is only possible to a limited extent. The carbon footprint depends, amongst other things, on the specific packaging design, the amount of material required, the type and quantity of coating, the energy used in production, transport routes and the respective end-of-life scenario.

     

    The basis for comparison is also crucial: the comparison should be made between functionally equivalent packaging solutions that guarantee the same level of protection and shelf life for the packaged product. A comparison based solely on weight or raw material may lead to an incomplete result.

     

    A life-cycle assessment (LCA) is therefore necessary for a robust evaluation. It should transparently outline the relevant life-cycle stages and assumptions, from raw material extraction and manufacture, through coating and transport, to collection, recycling or disposal.

     

    Paper has a natural advantage from the outset: the trees from which the paper fibres are derived absorb CO₂ from the atmosphere as they grow and store the carbon contained therein in their biomass. Some of this carbon also remains bound in the finished paper product. As a result, paper already has a favourable starting point in terms of its carbon footprint compared with many fossil-based materials.

     

    Barrier paper can offer advantages in terms of raw material sources and recycling in certain applications. However, these advantages cannot be assumed across the board for every type of barrier paper or in every comparison with plastic packaging. FSC or PEFC certifications can provide information on the certified origin and management of forestry-based raw materials.

     

    For selected Felix Schoeller products, therefore, the specific results of a robust, product-specific LCA will be decisive. This will specify, at a minimum, the product variant under consideration, the comparative packaging, the functional unit, the system boundaries, the data set and the end-of-life scenario.

     

    In short: whether barrier paper has a lower carbon footprint than plastic packaging can only be answered on a product-specific basis. The decisive factor is a concrete, transparently documented life-cycle comparison of a functionally equivalent packaging solution.

  • Are the fibres in Felix Schoeller’s barrier papers certified as sustainable?

    This depends on the specific product variant and the paper substrate used. FSC-certified fibres are used in appropriately labelled products from Felix Schoeller.

     

    The certification relates to the origin of the fibres used and/or to the controlled supply chain in accordance with the relevant certification standard. Which certification applies to a specific product depends on the product, the fibre used and the scope of the certification.

     

    FSC and PEFC certifications can demonstrate that the raw materials in question originate from certified sources and are sourced or monitored throughout the supply chain in accordance with the requirements of the relevant standard. However, they do not constitute general proof of all the environmental characteristics of the finished barrier paper and do not, for example, replace a product-specific assessment of the carbon footprint or recyclability.

     

    For specific details regarding a product’s certification, the relevant product documentation, the scope of certification and, where applicable, the corresponding chain-of-custody certification are therefore decisive.

Regulatory framework: PPWR, SUP & REACH

  • What is the EU Packaging Regulation (PPWR) and what does it mean for my business?

    The EU Packaging and Packaging Waste Regulation (PPWR) is the most comprehensive reform of European packaging legislation in decades. It replaces the previous Packaging Directive (94/62/EC) and, as a directly applicable regulation, will apply in all EU Member States (without scope for national implementation).

     

    Key requirements of the PPWR:

    • All packaging must be recyclable by 2030
    • Minimum proportions of recycled plastic (recyclates) are prescribed
    • Excessive packaging is regulated: packaging must be reduced to the bare essentials
    • Certain single-use packaging will be restricted or banned
    • Extended Producer Responsibility (EPR) will be harmonised
       

    Relevant to you: If your current packaging is not recyclable, action is required. Fibre-based barrier packaging from Felix Schoeller is designed to meet the PPWR requirements.

  • What does the Single-Use Plastics Directive (SUP) cover, and does it affect me?

    The SUP Directive (EU) 2019/904 aims to reduce single-use plastic products that often end up in the environment. Since 2021, certain single-use plastic products have been banned in the EU (e.g. plastic straws, cotton buds, single-use cutlery).

     

    As regards packaging: products that consist partly of plastic (including coatings) may be subject to labelling requirements or future restrictions. The exact definition is complex and is clarified by guidelines from the European Commission.

     

    Check: Does your current packaging contain any plastic components? Even as a coating or laminate? If so, you should assess its relevance under the Single-Use Plastics Directive and evaluate alternatives.

  • What does REACH mean for packaging materials and coatings?

    REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) is the European chemicals regulation. It governs which substances may be used in products (including packaging materials and coatings).

     

    The following are particularly relevant to packaging:

    • SVHC substances (Substances of Very High Concern): These must be declared if they are present in concentrations exceeding 0.1%
    • PFAS restrictions: Per- and polyfluoroalkyl substances (PFAS), which have previously been used as grease barriers, are increasingly subject to regulation and are set to be largely banned in the EU
    • Printing Inks Regulation: Regulates the ingredients of printing inks used on packaging 


    Our Felix Schoeller approach: Our barrier coatings are developed without PFAS. We actively monitor regulatory developments and ensure that our solutions remain REACH-compliant at all times.

  • Are barrier materials authorised for food contact (FCM)?

    Food contact materials (FCM) are subject to strict requirements in the EU. The Framework Regulation (EC) No 1935/2004 stipulates that materials must not transfer any substances to food that pose a risk to health or that unlawfully alter the composition of the food.

     

    There is currently no harmonised EU regulation for paper and board (unlike for plastics). National regulations apply, as do the recommendations of the Federal Institute for Risk Assessment (BfR) in Germany.

     

    Felix Schoeller develops barrier papers for food contact, taking into account all relevant national and European requirements, and issues the corresponding declarations of conformity (DoC).

Areas of application & product examples

  • For which types of food packaging are barrier papers particularly suitable?

    Barrier papers are particularly well suited to dry and semi-dry product ranges, as well as to products containing fat. The main areas of application are:

    • Butter wrappers: fat barrier, moisture protection, food contact
    • Dry foods: powders, rice, pasta, pulses – moisture barrier essential
    • Confectionery & chocolate: fat and moisture barrier, flavour retention
    • Snacks: oxygen and moisture barrier to preserve freshness
    • Bakery & baking mixes: fat barrier, freshness retention
    • Ice cream: Moisture and fat barrier, suitability for deep-freezing


    Where barrier paper is not (yet) suitable: liquids, drinks and products with a very long shelf life under extreme conditions are currently still the domain of plastic or aluminium.

  • Are there any non-food applications for barrier papers?

    Yes, the non-food sector also offers attractive areas of application for fibre-based barrier packaging:

    • Household and personal care products: e.g. dishwasher tablets, laundry detergent pods = moisture protection and product stability
    • Seed packaging: moisture barrier to ensure germination
    • Pet food: dry pet food with fat and moisture barriers
    • Pharmaceuticals & healthcare: selected applications with specific barrier and hygiene requirements

    However, industrial chemicals, aggressive solvents or products requiring direct contact with liquids are
    not suitable.

  • Can barrier papers be printed on?

    Yes, barrier papers can be printed using standard printing processes, including flexographic printing, gravure printing, digital printing and inkjet printing. Printability depends on the surface characteristics of the paper and the coating used.

     

    Important: The printing inks must be suitable for the intended use; in particular, where there is contact with food, strict requirements apply regarding the migration safety of the printing inks (Printing Inks Regulation, Swiss Ordinance).

     

    Our tip: Discuss the choice of printing inks at an early stage with your printing partner and Felix Schoeller. This will help you avoid any surprises during the conformity assessment.

Collaboration & Co-creation

  • What exactly does ‘co-creation’ mean at Felix Schoeller?

    At Felix Schoeller, co-creation means: we offer both standardised and bespoke products, and work together with you and our partners to develop a solution that is precisely tailored to your requirements, machinery and supply chain.

     

    This begins with a joint reality check: we analyse your current materials, barrier requirements, machine parameters and regulatory risks before proposing a solution. Our guiding principle: “We diagnose before we design.”

     

    The process comprises four phases:

    • Reality Check: Analysis of your current situation
    • Impact & Risk: Assessment of costs and regulatory risks
    • Solution Design: Development of the bespoke solution
    • Validation: Prototyping, machine trials, proof
        of scalability

    “Most customers know exactly what their current packaging requirements are, but they are not always aware of the technical limits of a new material. This is because paper behaves differently to plastic or aluminium. That is why we work together to develop packaging that combines product-specific requirements with practical processing. It is precisely this combination of paper expertise, technological understanding and co-creation that makes Felix Schoeller special.” 

    – Daniel Zimmermann, Head of Sales Packaging, Felix Schoeller

  • What happens during an initial meeting with Felix Schoeller?

    An initial meeting with Felix Schoeller is straightforward and non-binding. We’ll start with a brief introductory chat to gain an understanding of your current packaging situation, your sustainability goals and your timeline.

     

    Ideally, please bring the following:

    • Information about your current packaging materials
    • Your key barrier requirements (moisture, grease, oxygen)
    • Details of your packaging machinery
    • Your regulatory requirements (food contact, certifications)
       

    On this basis, we can quickly assess whether and how we can help you and suggest a specific next step.

  • Does Felix Schoeller also work with smaller companies and start-ups?

    In any case, Felix Schoeller is open to partnerships across the entire value chain. Our focus is on brand owners, converters and fillers who are seeking to make a significant transformation to their packaging solutions.

     

    For smaller companies and start-ups, we recommend starting with a clearly defined pilot project; this enables focused collaboration with manageable effort on both sides.

  • Does Felix Schoeller also offer small-batch production and prototyping?

    Prototyping and small-batch production are an integral part of our development process. We understand that, before deciding to go into mass production, you need to test samples, carry out machine trials and conduct consumer tests.

     

    Our agile development infrastructure enables rapid prototyping: from the first prototype to a scalable industrial solution, we support you at every stage. Always with the aim of minimising development cycles and shortening time-to-market.

Comparison: Barrier paper vs. plastic & alternatives

  • Why should I switch from plastic packaging to barrier paper?

    There are four compelling reasons to make the switch:

    • Regulatory requirements: The PPWR and SUP Directives are increasing the pressure on non-recyclable packaging. Those who act now will be on the safe side from a regulatory perspective
    • Brand image: Consumers and retailers expect sustainable packaging. Paper is perceived as more natural and sustainable than plastic
    • Circular economy: Paper is well established in Europe. The supply of raw materials is guaranteed and the recycling cycle has proven its worth with high collection and recovery rates


    Honest assessment: The switch is not always easy and is not immediately feasible for every application. In certain areas, barrier papers are not yet fully equivalent to high-performance plastics. We can help you make a realistic assessment of where the switch makes sense today.

  • Is barrier paper more expensive than plastic packaging?

    Honest answer: At first glance, yes – at least when comparing the materials directly. Barrier papers are more complex to manufacture than simple plastic films, which is reflected in the material cost.

     

    However, the cost of the material alone is only part of the overall picture. The following factors must also be taken into account:

    • Licence costs: Rising EPR levies for non-recyclable packaging and their adjustment
    • Regulatory risks: Costs associated with subsequent changes under time pressure
    • Brand positioning: The value of sustainable packaging for brand image and customer loyalty, as those who pioneer new approaches early on benefit from visibility, differentiation and strong positioning
    • Economies of scale: As volumes increase, the costs of barrier papers fall


    Our approach: In the Impact & Risk Assessment, we work with you to analyse the total costs, not just the material price. Often, the business case for barrier paper is better than expected.

  • What sets Felix Schoeller apart from other suppliers of barrier paper?

    The market for barrier papers is growing, and with it the number of suppliers. What sets Felix Schoeller apart:

    • Technological depth: Our own 5-layer curtain coating technology and in-depth substrate expertise
    • A co-creation approach: We work with you to develop solutions throughout the value chain
    • Proven recyclability: We demonstrate recyclability using recognised testing methods
    • Agility: We place a strong emphasis on flexibility and customisation
    • Specialisation: For us, packaging is a strategic core competence based on our expertise in the field of photographic, release and decorative papers
  • What trends are shaping the future of the packaging industry, and how is Felix Schoeller positioning itself?

    The packaging industry is undergoing fundamental change. The key trends are:

    • Regulatory pressure: PPWR, SUPD, PFAS bans and extended producer responsibility are creating a clear framework for sustainable packaging
    • Circular economy: ‘Design for Recycling’ is becoming the norm – packaging must be designed with the circular economy in mind from the outset
    • Digitalisation: Digital product passports and traceability are becoming mandatory – including for packaging
    • Consumer expectations: Transparency regarding materials and sustainability performance is becoming a key purchasing criterion
    • Technological innovation: New coating technologies enable ever-better barrier performance whilst also improving recyclability


    Felix Schoeller’s positioning: We are the experienced partner for sustainable, fibre-based flexible packaging solutions in Europe. Our aim is to connect and empower the entire value chain. We are developing solutions today that will be the new standard tomorrow.

     

    The packaging industry is facing a transformation that we are actively helping to shape. PPWR is not a risk – it is an invitation. Those who invest in fibre-based solutions now will not only ensure regulatory compliance but also secure a genuine competitive advantage.

    - Guido Hofmeyer, Head of the Packaging Segment, Felix Schoeller

Authors

Portrait Daniel Zimmermann

Daniel Zimmermann

Since February 2025, Daniel Zimmermann has been Head of Sales & New Business Development Packaging at Felix Schoeller, where he is responsible for international sales and business development for paper-based barrier packaging. Previously, he worked in global new business development at Nissha Metallizing Solutions and Eurofoil Paper Coating, focusing on barrier and laminate solutions. He now draws on this experience to support companies in developing packaging solutions that are suitable for recycling and tailored to their products and processes.

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Portrait Andreas Bergmeier

Andreas Bergmeier

Andreas Bergmeier has experience of packaging from virtually every angle: from technical development and application engineering, through sales and business development, to international management roles. Close collaboration with customers, suppliers, brand owners and partners throughout the entire supply chain has shaped his approach to successful innovation. His focus is on translating customer requirements, sustainability and commercial success into practical and future-proof concepts.

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Portrait Maximilian Deutsch

Dr Maximilian Deutsch

Dr Maximilian Deutsch has been working in the Research & Innovation department at Felix Schoeller since mid-2022. Having held various roles across different business segments, he has been responsible for development in the Packaging division since January 2025. His degree in physical chemistry and his early career at a start-up specialising in smart packaging labels form the basis of his expertise. He sees the transition to fibre-based packaging solutions as an important step towards a more sustainable economic system in which resources are used efficiently.

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