Paper-based flexible packaging

Paper-based flexible packaging means pouches and wraps made mostly of paper by weight, with plastic or barrier components limited to thin coatings or layers. The goal is to keep useful protection while allowing the pack to be recycled with paper.

Not the same as a kraft pouch

A classic kraft pouch has paper outside but a thick PE liner and often metallised film or foil inside. It looks like paper but cannot be recycled as paper. Paper-based structures keep the plastic content low and rely on water-based barrier coatings, heat-seal lacquers or very thin polymer layers.

Where it works

Dry foods such as flour, sugar, pasta and rice; confectionery and bar flow packs; nuts and granola; and increasingly coffee and tea as barrier coatings improve.

Limits

• Barrier is usually lower than foil or EVOH plastic structures
• Paper weakens when wet and can crack at folds; liquids and heavy products are generally unsuitable
• Narrower sealing window, so filling lines may need adjustment
• Recyclability claims need test evidence, not just a high paper share

Test sample pouches with your real product and filling line, and compare against recyclable mono-material plastic options before deciding.