Recyclable dry food packaging for flow wrap

UAB "Skanėja" has been a household name in the Baltic dry food sector for over 20 years, trusted for packing everyday staples like grains, beans, and sugar. For two decades, their operations relied on a standard Paper/PE (Polyethylene) laminate. While functional, this "Composite" material became a liability due to rising EPR tariffs and recycling complexities.

The client wanted to transition to a sustainable future but feared operational risks:

• The Operational Fear: Changing a material that has worked perfectly for 20 years is risky. Any deviation in stiffness or sealability could cause jams, sealing failures, or slow down high-speed production.
• The Requirement: The new solution had to be a "ghost" replacement—visually identical to maintain brand recognition and mechanically invisible to the machines, while delivering genuine eco-benefits.

We implemented a "No-Shock" transition strategy using our advanced heat-sealable barrier paper. Instead of forcing the client to upgrade their machinery, we engineered the paper to fit the machine. Our technical team carefully calibrated the paper's tensile strength and stiffness to match the legacy laminate, ensuring a seamless switch.

Transition benefits:

• Seamless Integration: A true "drop-in" solution. The production team experienced zero disruption or speed loss during the switch from plastic laminate to barrier paper.
• Sustainability Upgrade: The packaging shifted from "Mixed Waste" (C/PAP) to the standard recyclable "Paper Stream" (PAP 22), satisfying both retailers and eco-conscious consumers.
• Weight & Cost Efficiency: By removing the heavy PE layer, we significantly reduced the total packaging weight, generating savings on both material costs and logistics.