Sustainability and recycling are more in demand among consumers than ever before. Recent studies confirm that consumers worldwide are willing to pay more for products with environmentally friendly packaging and are increasingly basing their purchasing decisions on sustainably packaged products. With growing consumer interest, as well as demands from legislators, the pressure on companies in the food, bakery and other industries is increasing - and sustainability is also becoming an image issue. This makes it all the more important to develop more environmentally friendly packaging solutions, conserve resources and produce more efficiently.
A sustainable mindset knows no national borders. In Europe and the United States, consumers value ecologically manufactured products when shopping. As reported in the 2024 ‘Sustainability, EV, and Convenience Retail Survey Report’, 71 per cent of US consumers over the age of 21 were willing to choose the sustainable option over a similarly priced product1. Data from Aula Research on consumer behaviour in Finland in 2024 reveals a similar trend: more than one in three respondents said they would be willing to spend a little more for more sustainable packaging. Eight per cent would even be willing to pay significantly more for a product with sustainable packaging.
Sustainable, and wherever possible, recyclable packaging solutions are therefore becoming a long-term challenge for the packaging industry and for its customers. In Germany alone, several million tons of packaging waste are generated every year. New approaches to packaging are needed to reduce this amount over the long term and to significantly increase recycling rates. But how can manufacturers use more sustainable materials in the packaging process while remaining profitable? And what technologies should they be considering?
If companies are looking to make their production more sustainable, they can tackle the issue from various angles. For example, they can use packaging materials that are environmentally friendly because they are easy to recycle, or they can try to reduce the amount of material used in their packaging.
Dotlock technology: using perforations instead of glue
Because it is made from renewable raw materials, cardboard packaging comes across as sustainable at first glance. However, it is as a rule not entirely recyclable due to the glue used to seal the cardboard packaging. This glue is very energy-intensive to produce and also requires the glue mass to be heated before it can be applied.
An alternative approach has been developed by packaging machine manufacturer Schubert. The company has developed an innovative technology that enables glueless cardboard packaging. Although Schubert’s main business focus is on the development of modular, digital and robot-based packaging systems, the company also develops sustainable packaging concepts as an innovation driver for the packaging industry.
With its new Dotlock technology, several layers of cardboard can be joined completely glue-free by reshaping them, similar to clinching metal. To achieve this, the layers are pierced from one side with a needle, creating a collar on the other side. This is then pressed onto the cardboard, creating a stable force and form fit. During the Dotlock process, the carton blank is erected simultaneously and can therefore be easily integrated into Schubert’s standard process chain.
This ensures that the cardboard packaging achieves the same strength as with a glued connection. The main advantage is that the mono-material cardboard packaging is fully recyclable. With Dotlock, companies can save resources and strengthen their image as an environmentally friendly company wherever solid cardboard packaging is used.
Innovative technologies for sustainable packaging
It is generally accepted that plastic films are virtually irreplaceable in the packaging industry due to their barrier properties. The recyclability of materials is essential to ensure that companies in the food and other industries can nonetheless operate sustainably. Monofilms, which consist of a single plastic, are the most easily recyclable. However, monofilms are primarily made of PP and therefore have a lower melting point than composite films. As a result, heat-sealing processes are not suitable for single-material variants.
A gentle sealing process is needed to use monofilms in flow-wrapping machines. And this is precisely what Schubert’s Flowpacker series delivers. Among other things, it features Box Motion sealing technology, which is suitable for recyclable flowpacks made from monofilms and even paper-based films. Thanks to their gentle ultrasonic sealing process, the machines are an excellent choice for polymers with a low melting point and do not require heat protection.
Sustainability in the packaging industry also calls for flexibility. It isn’t uncommon for food manufacturers to package different products in order to cover market segments as broadly as possible. This diversity has a significant impact on packaging processes, which manufacturers need to continuously adapt – for example, in terms of the packaging materials used. Flow-wrapping machines from Schubert enable switching between different sealing technologies, product formats and packaging materials.
In cases where the shelf life calls for laminated films, for example, Flowpackers can package the products accordingly. The use of more sustainable materials, such as bioplastics, is also possible in the same machine as long as the product allows it. For this purpose, different sealing units can be exchanged easily and quickly. The packaging machine’s modular design makes it a cost-effective option for customers – and makes the use of sustainable packaging solutions even more attractive.
Less material
In addition to the use of more sustainable materials and their recyclability, the size of the packaging plays a decisive role in terms of ecological considerations. Saving a few millimetres per packaging unit can lead to significant material savings overall – from which the manufacturer benefits economically while conserving natural resources. However, smaller packaging sizes can only be implemented if they can be filled without compromising on quality. Schubert’s pick & place robots, for one, ensure that confectionery products such as bars or pralines are placed with millimetre precision into trays, boxes or thermoformed packaging – and they work significantly faster and more precisely than humans.
A firm commitment to sustainability and the conservation of valuable resources are compelling reasons for companies to make their packaging and processes more sustainable. Modular packaging machines, versatile robotics and innovative packaging materials provide valuable leverage. With partners like Schubert, manufacturers can set these levers in motion – and ultimately meet high consumer expectations.