Bobst, Michelman advance recyclable high-barrier solutions for PPWR compliance

Bobst and Michelman are expanding their long-standing collaboration to accelerate the development of recyclable, high-barrier packaging solutions aligned with upcoming EU regulations.

Speaking at interpack 2026, the two companies outlined progress in developing mono-material and fiber-based structures designed to replace conventional multi-layer plastic packaging while maintaining performance. The work is being driven in part by the European Union’s Packaging and Packaging Waste Regulation (PPWR), which will require all packaging to meet minimum recyclability thresholds by 2030.

The partnership combines Michelman’s expertise in water-based functional coatings with Bobst’s capabilities in vacuum metallization, coating and converting. Together, the companies have developed solutions that integrate barrier performance into recyclable structures without compromising shelf life or production efficiency.

Among the key developments is oneBARRIER PrimeCycle, a mono-material polyethylene solution designed for high-barrier flexible packaging. The structure uses MDO-PE film with ultra-thin functional layers and has achieved recyclability scores of up to 98%, while delivering oxygen and moisture barrier performance comparable to aluminum foil.

The companies also highlighted progress in paper-based packaging with oneBARRIER FibreCycle, which uses a combination of primer coatings, vacuum metallization and heat-sealable topcoats to deliver barrier performance on substrates that inherently lack protection. Testing has shown strong oxygen and moisture barrier properties, alongside high recyclability through established industry protocols.

Looking ahead, Bobst and Michelman are also exploring bio-based and plastic-free coating systems, as well as ultra-thin film lamination approaches that can further enhance barrier performance while reducing material usage.

Van Migem spoke at interpack 2026, held in Dusseldorf, with Nick Copeland, R&D Director – Barrier Solutions at Bobst.

“We cannot give in on performance,” said Thierry Van Migem of Michelman. “People want their products to retain the same shelf life.”

The companies emphasized that collaboration across the value chain will be critical as converters work to meet PPWR requirements. With the regulation set to take effect in 2030, the focus is shifting from concept development to scalable, industrialized solutions that can be deployed across packaging applications.

“We needed to get the same barrier performance on much more challenging, less performing substrates,” explained Nick Copeland. “That performance had to be achieved but also maintained through each conversion step.”