FACHPACK 2024: Transition in Packaging – Report

The European trade fair for packaging, technology and processes was held under the motto “Transition in Packaging” this year – a reference to the strong currents that are currently affecting the packaging industry. Legislators and consumers are demanding sustainability – and this is profoundly influencing and changing the packaging industry. We were at FACHPACK in Nuremberg from September 24 to 26, 2024, and discovered some interesting new packaging solutions. There was also a highly anticipated premiere: the ‘Women4Packaging’ networking event took place for the first time and was an absolute highlight, not least thanks to the great moderation by Sonja Bähr, our Director of Business Development at Berndt+Partner Creality.

General impressions of FACHPACK 2024

As mentioned at the beginning, the topic of sustainability played a central role at FACHPACK 2024. It was omnipresent. However, one difference to previous years was in the communication of the subject: companies have become more cautious about presenting and promoting sustainable features and ideas. In addition, we saw only a few new companies at the show and no major innovations. This lack and the noticeable reluctance can be primarily attributed to new legal regulations, in particular the EU Packaging and Waste Guidelines (PPWR). The latter were also a major topic at FACHPACK. It was striking how many small companies and start-ups presented reusable shipping packaging. In general, the focus was on reusable solutions to promote the circular economy that is being strived for.

Highlights in packaging materials

Paperization

Paperization is still in vogue. Companies are still trying to replace plastic packaging with cardboard packaging. Some companies are also experimenting with using other natural raw materials to produce packaging in order to conserve wood as a resource. The tests are quite promising. Currently, it seems that a wide variety of materials could be suitable for manufacturing paperboard-like packaging. These include, in particular:

grass
bagasse
hemp
straw
rice straw
bamboo
seaweed
algae

The key requirement is that packaging made from these alternative raw materials also works in the waste paper stream and that fiber recycling is achieved. If this is successful, “paper packaging” could soon be made from a wide variety of natural materials.

The wax coating of paper is particularly important in the food industry. In this context, more environmentally friendly solutions were presented at the trade fair: for example, the bio-based barrier coatings from WAX Solutions GmbH are 100 percent fossil-free and recyclable.

Likewise for the food industry, paper made from ground limestone is extremely promising. The solution from STP Stone Paper Products GmbH consists of up to 80 percent stone paper and about 20 percent additives. It is water-resistant and food-certified. And: stone paper can be printed using offset or UV printing.

Reusable packaging concepts

At FACHPACK 2024, reusable packaging solutions were presented at numerous, mostly small, stands. Two concepts stood out for us: one for bulk stores and one for pizzerias.

Environmentally conscious consumers, who often shop at bulk stores, could be delighted with the INTO refill packs. The container with an integrated cloth bag is lighter than glass and more sustainable than a plastic bag. It can be reused almost endlessly to bring rice, legumes or pasta from your favorite bulk store home safely. Considering that the ban on single-use plastic for packaging fruit and vegetables will come into force in 2030, this design has the potential to form the basis for further sustainable packaging solutions.

“Pizza without all the waste!” This is the slogan used by tornerò GmbH in Regensburg to advertise its interesting deposit system for pizzerias. And this is how it works: the partner pizzeria delivers its pizzas in tornerò’s special plastic pizza boxes and charges a deposit of six euros for each box. After enjoying the pizza, the consumer returns the box. This way, the consumer gets their deposit back and at the same time contributes to reducing waste and thus to protecting the environment. The box can be cleaned each time and reused up to 500 times. And the best thing is: at the end of its service life, the manufacturer from the Allgäu region recycles 100 percent of the pizza boxes’ material and uses it to create transport boxes. Incidentally, the Italian company name is very aptly chosen, because “tornerò” translates as “I will come back”.

Alternative materials

At the SOLPACK forum, Pacoon GmbH presented various sustainable packaging solutions made from alternative materials such as grain husks. The compostable tea bags made from algae were another highlight at the trade fair. They are fully biodegradable and thus help to reduce plastic waste. Similar packaging could be used for other foods in the future.

Outstanding packaging machines

We found two outstanding packaging machines: one for cardboard trays and one for producing sample packs with innovative opening technology.

Syntegon has developed a cartoning machine that produces interlocking carton trays instead of glued ones. This means that no glue is needed for production. Apart from the fact that a lot of glue is saved, there is also no need to heat the glue. All this reduces CO2 emissions by around 30 percent. The modified manufacturing method has no effect on productivity: The machine works just as fast, so there is no risk of losing time.

Would you like to have sample packages of certain foods, cosmetics, medical, pharmaceutical or chemical products that can be easily opened with one hand, do not waste a single drop or crumb, and also guarantee a high level of hygiene and safety? The innovative machine from the Italian company V-Shapes makes it possible. It produces small sachets that can be emptied by simply folding them in the middle with one hand. In addition to the easy handling, the complete emptying of the sachet is particularly impressive. The packaging and the technology are patented. Incidentally, the practical sachets can be made largely from bio-based and recyclable materials, making them convincing from a “green” perspective as well.

Exciting winners of the German Packaging Award

Traditionally, the winners of the German Packaging Award are honored at FACHPACK. Of course, we also paid close attention to which innovations particularly impressed the jury at this year’s award ceremony. Our three favorites are briefly presented below. In general, topics such as recyclability, material substitution and adaptation to the new regulations also dominated here again.

ReZorce Circular Packaging from Zotefoams in Great Britain

This new packaging represents a sustainable alternative to classic beverage cartons. It consists of 100 percent HDPE. Thanks to Zotefoams’ patented technology, it is even possible to use 30 to 70 percent mechanically recycled HDPE. During extrusion, a layer is applied – this step has an extremely positive effect on the barrier properties of the material. Producing the packaging from HDPE demonstrably uses around 50 percent less water and energy than manufacturing conventional composite cardboard packaging.

Paper net from Knüppel Verpackung GmbH & Co. KG in Germany

With the so-called paper net from Knüppel, companies can reduce the plastic content of their packaging without loss of performance. It consists of several layers of testliner paper and has almost the same damping properties as PE foam. The structure of the net is designed to bounce back after impacts, so that it retains its protective function.

Reusable bottle for cooking oil from Bio Planète in Germany

In collaboration with system provider dotch, Bio Planète has developed a reusable bottle for cooking oil. After use, the bottle can be returned at a deposit machine in organic food stores and refilled up to 50 times before the glass is recycled. Every oil producer or brand has the option of using this bottle to distribute their own products. The system’s holistic approach involves all players in the logistics chain and builds on the existing infrastructure. As a result, there are no major hurdles to overcome during implementation.

The celebrated premiere of Women4Packaging at FACHPACK 2024

The ‘Women4Packaging’ networking event took place for the first time at FACHPACK. It offered the participants a special opportunity to network and exchange ideas on current topics in the packaging industry. The background to the event is quickly explained: although there have been numerous qualified women in the packaging industry for a long time, they often lack networks and opportunities for constructive dialog with each other. This is precisely what Women4Packaging wants to change. The event offers women from the packaging scene the opportunity for effective networking.

Our Director of Business Development, Sonja Bär, moderated the lively panel discussion with Ina Bechter (Pacoon), Katja Kilian (BU Flexibles Business Development Director at Coveris), Mareike Peters (founder of nmk) and Ellen Reichmann (Group Leader Application Engineering and Product Protection at Syntegon). Around 150 women attended the premiere of Women4Packaging and were happy to be motivated by keynote speaker Vera Strauch (founder of the Female Leadership Academy) to strengthen and inspire each other. The event was a great success.

“Be self-confident, don’t pay attention to appearances and role models, and support each other unconditionally instead of seeing and treating each other as competitors!” This was the basic message of Women4Packaging. After the “stage program”, the participants were able to get together in smaller groups in a relaxed atmosphere with delicious finger food and cool drinks and talk about their activities and industry-specific topics, exchange contact details and thus create the basis for a strong women’s network in the packaging industry.