Sustainability in packaging is no longer just about innovation, it is about collaboration, scalability, and preparing the industry for fast approaching regulatory deadlines. In our latest interview, BOBST and Michelman share their thoughts on circular packaging, recyclable flexible materials, and what it will take to make sustainable solutions commercially viable at scale.
BOBST’s sustainability strategy focuses heavily on circular packaging and mono-material solutions like oneBARRIER. What do you see as the biggest challenge in making recyclable packaging commercially scalable across the industry?
One of the biggest challenges is the time needed for converters to scale up to be ready with industrialized solutions. This process takes longer than many anticipate for two main reasons. First, there is the complexity of identifying the right solutions and developing the most effective production process. Second, there are equipment considerations, which may involve the integration of existing equipment and/or investment in new technologies or partnerships.
With expertise spanning R&D, an extensive portfolio of innovative equipment, and the means to test production methodologies, BOBST can support all stakeholders along the value chain, from material suppliers to printers, converters and brand owners.
Sustainability deadlines are fixed and many converters are underestimating what that means. The current geopolitical climate is causing people to hold back a little, but if the industry is to be ready by 2030, now is the time to move.
I read that BOBST collaborates with initiatives like CEFLEX and the 4evergreen Alliance to improve recyclability and fibre recovery. How important are cross-industry partnerships in accelerating sustainable packaging innovation?
They are fundamental. Only by working together can the entire end-to-end process be completely optimized. Success depends on collaboration across the entire value chain, and that philosophy is central to how we operate at BOBST.
We partner with customers, brands, material suppliers and industry alliances such as CEFLEX and 4evergreen to make sure that what we bring to the market in terms of solutions are actually viable, certified, and meet the legislation. That said, collaboration in itself does not always mean solution. Collaboration cannot be about “name dropping” or a “me too” opportunity. True collaboration requires genuine co-creation, combining deep expertise, sharing knowledge, and working collectively to develop new solutions that address complex challenges, all while leaving egos at the door.
When we do this, we further bridge the gaps between R&D and future innovation, enabling the commercially viable solutions of our future.
BOBST talks about balancing sustainability with industrial performance, particularly through energy-efficient machines and reduced material waste. How do teams measure whether a new innovation delivers both environmental and commercial value?
We must be able to measure our solutions and there are different ways of doing this. At BOBST, this starts with data. In terms of our equipment, we are very focused on data management which is possible thanks to connectivity and supported by automation and digitalization of our processes, which together with sustainability, are the four pillars of our industry vision. Thanks to all of the above we can measure and improve efficiency and productivity and therefore minimize waste and reduce energy consumption. One practical example is BOBST iMA, which is an AI-powered vision system for the vacuum metallizing industry . It significantly reduces waste and increases output therefore ticking all the boxes; measured solutions, more sustainable, improved efficiencies and therefore increasing commercial value for our customers. Other solutions include the oneSET function on our Gravure printing presses, which suggests the most suitable and efficient machine settings on its own, meaning a fast and accurate machine set-up; and energy monitoring via our BOBST Connect platform, which provides a clear, data-driven view of how much energy each machine is using, what it’s costing, and how much CO₂ is emitted along the way.
With increasing EU regulations around packaging waste and recyclability, how is BOBST helping customers future-proof their packaging operations while remaining competitive?
Future proofing solutions means looking at sourcing, machinability and cost. As the industry continues to innovate, a wide range of solutions are being explored. Over time, we expect a smaller number of proven approaches to emerge as industry standards, enabling broader adoption and helping drive down costs.
In terms of R&D, BOBST continuously supports converters and brand owners in the research and development phase for new solutions or to fast track innovations via already proven solutions developed in BOBST competence centers.
What should not be taken for granted is the process side. It is not only about sourcing the right materials, but ensuring practical application and repeatability, which means the right choice of equipment and methodology as well as strong process know how. These are key areas where BOBST is currently supporting the market, whether for converters, brand owners, or others in the value chain.
BOBST aims to make its Packaging Use & End-of-Life stream a recognised driver of environmentally improved packaging by 2030. What sustainability milestones is the company most focused on achieving over the next few years?
We will continue to work on the energy efficiency and environmental sustainability of our machines. In addition, we will further develop new sustainable packaging solutions with our partners, based on the three pillars that have driven our processes in R&D for many years: mono material PE or PP based structure, biodegradable and compostable, and fibre-based packaging.
Michelman emphasises that sustainability should be the goal, not just an added benefit. How does the company balance demanding packaging performance requirements, such as oxygen and moisture barriers, with recyclability and circularity goals?
Michelman’s position is clear: sustainability must be the objective itself—not merely a side benefit. This mindset creates a genuine engineering tension, as high-performance packaging—particularly for food and sensitive goods—has traditionally relied on complex multilayer structures and materials that are difficult to recycle. Balancing performance with sustainability requires purpose-designed, multifunctional barrier coatings. Michelman addresses this challenge by replacing structural complexity with functional coating technologies, enabling mono-material and fiber-based solutions that remain compatible with existing recycling systems.
Across all of our developments, we are guided by a clear ambition: to optimize performance within a circular system—delivering high-quality packaging solutions while advancing recyclability, compostability, and resource efficiency.
I noticed Michelman works closely across the value chain with converters, OEMs, and material suppliers to develop production ready sustainable packaging. What have been the biggest lessons learned from this collaborative approach to innovation?
For many years, we have been strong advocates of value chain innovation and collaboration. Our journey with BOBST, which began 13 years ago, has resulted in several successful co-creation achievements, including protective coatings for AlOx and high-barrier solutions within the “OneBarrier” paper and film family. UPM Specialty Materials, providing carefully selected papers for the oneBARRIER FibreCycle structures, is another key partner in this collaboration. By bringing together expertise from across the value chain, we have demonstrated our ability to accelerate innovation and significantly reduce time to market. This collaborative approach enables us to support our partners in fast-tracking their high-barrier R&D projects and delivering sustainable, high-performance solutions more efficiently.
Michelman’s water based coatings are designed to help replace traditional plastic heavy packaging structures with recyclable or compostable alternatives. Which emerging sustainable packaging technologies do you think will have the biggest industry impact over the next few years?
Michelman’s innovative product portfolio strongly supports industry design-for-recycling guidelines across multiple packaging streams—ranging from the transition to recyclable mono-material films to high- and medium-barrier solutions that enable paperization. These trends are expected to accelerate in the coming years, driven by regulatory frameworks such as the PPWR and evolving design criteria. In parallel, bio-based and plastic-free barrier coatings will continue to gain momentum as emerging sustainable packaging technologies. They offer dual end-of-life benefits, comply with SUPD requirements for applications such as food service, and have the potential to reduce EPR eco-modulation fees.
Michelman frequently highlights innovation in mono material and paper based packaging solutions. What do you see as the biggest remaining technical barrier to scaling truly recyclable flexible packaging globally?
The biggest remaining technical and structural obstacles to scaling truly recyclable flexible packaging globally can be summarized across four key dimensions.
The first dimension relates to alignment to regulations and design guidelines. The implementation of frameworks such as PPWR, combined with global EPR eco-modulation schemes, is a strong accelerator—but fragmentation across countries still creates complexity. Harmonized criteria are essential to enable scalable innovation and avoid multiple design standards for the same application.
The second dimension includes achievement of the required barrier performance especially for sensitive products combined with barrier resilience throughout the product lifecycle (processing, filling, transport, and storage). This is where advanced, multifunctional coatings play a key role, and continuous innovation is ongoig to fully match the performance of multilayer structures.
Designing for recyclability is only part of the equation—solutions must also be effectively collected, sorted, and recycled in real-world systems. Ensuring compatibility with existing recycling infrastructures, both for polyolefin mono-materials and fiber-based solutions, is essential to deliver true circularity at scale.
Finally, cost remains a key barrier to widespread adoption. While sustainable solutions deliver clear environmental benefits, there is still a need to balance performance with commercially acceptable on-cost levels. The combination of regulatory incentives, scale effects, and continued innovation will be critical to closing this gap.