Beverage packaging is currently undergoing intensive changes driven by regulations, sustainability targets and shifting consumer preferences. At interpack 2026 in Düsseldorf, international suppliers of beverage filling and packaging technologies will demonstrate how combining packaging lightweighting, advanced barriers, digital process control and improved recyclability is shaping new generations of packaging systems for the beverage industry. The solutions include lightweight bottles made of rPET, new barrier coatings, labels designed for the circular economy and adhesives that facilitate recycling, as well as label-free marking technologies and the developing segment of cans and cartons for beverages.
Lightweight rPET bottle and glass barrier from KHS
One of the key development directions is further reduction of material usage in PET bottles. KHS is implementing a premium lightweight concept and presents the Premium Lite bottle for still water, made entirely from recycled PET. With a volume of 0.25 litres, the bottle weighs only 6.2 g. The package is designed to combine minimal raw material consumption with high visual quality and has been adapted to the requirements of modern high-speed lines.
The lightweight bottle is produced on KHS InnoPET Blomax Series V stretch blow moulders, which ensure process stability at high throughputs and high forming precision. The use of such machines makes it possible to maintain quality parameters despite very thin bottle walls.
KHS is also developing barrier solutions that support the circular economy. The new Supreme PET bottle uses Plasmax technology, in which a silicon oxide coating with a thickness of less than 100 nm is applied to the inner bottle wall. The coating behaves like glass and protects oxygen-sensitive beverages, such as high-quality green tea, from oxidation, extending their shelf life many times over.
At the same time, the bottle remains fully recyclable. In the recycling process, the thin glass layer is removed in an alkaline solution without contaminating the PET stream. The combination of a high level of product protection, compatibility with rPET and production speeds of up to 60,000 bottles per hour demonstrates how barrier technologies are being adapted to the requirements of the circular economy.
The KHS Supreme bottle combines PET with an ultra-thin internal glass coating. Image: KHS
Labels and sleeves designed for recycling
In parallel with reducing material usage, the recyclability of individual packaging components, including labels and adhesives, is gaining importance. CCL Label, an exhibitor at interpack 2026, focuses on solutions that support the circular economy and shows how label design can facilitate the operation of recycling systems.
In the segment of labels and shrink sleeves, CCL Label uses concepts that are compatible with recycling. The EcoFloat solution is a shrink sleeve made of low-density polyolefin. In the PET bottle recycling process based on the sink–float separation, the sleeve material floats, while the PET flakes sink to the bottom. This physical separability is crucial for high-quality bottle-to-bottle recycling.
EcoFloat White is a new option intended for light-sensitive products. It enables producers to switch from opaque HDPE or PET bottles to clear PET bottles while maintaining the required light protection.
In the reuse and refill segment, including returnable systems, CCL Label offers WashOff labels. These pressure-sensitive labels detach from glass and PET bottles in a caustic bath without leaving any residue, supporting the circulation of reusable packaging. In addition, EcoShear adhesive technology improves the recyclability of single-use glass bottles, as self-adhesive film labels can be almost completely removed from the container surface.
WashOff labels can be removed from reusable bottles without leaving any residue. Image: CCL Label
Label adhesives designed for recycling
The composition of seemingly secondary components such as label adhesives is also gaining in importance. Henkel Adhesive Technologies has developed a new hot-melt labelling adhesive that does not contain mineral oil and achieves a removal rate of up to 98 percent in the recycling process. Adhesive residues are separated from the main material stream together with the remains of labels.
The adhesive solution is compatible with both paper and plastic labels and ensures stable operation at speeds of up to 40,000 bottles per hour. At the same time, relatively low processing temperatures in the range of 110–140°C are maintained, which reduces equipment stress, allows energy savings and improves the operational reliability of labelling lines.
Laser marking instead of conventional labels
An alternative to conventional labelling is complete elimination of labels. Krones has developed the DecoBeam solution for direct marking of PET and rPET bottles. Key information such as the beverage’s net volume, list of ingredients, best-before date and graphic elements is applied directly to the bottle surface with a laser beam. This makes it possible to reduce packaging material consumption and simplifies the recycling process.
Two laser marking methods are available. CO2 lasers create markings with a light, whitish colour, while fibre lasers generate black lettering. In addition to text, logos, graphics and other visual design elements can be reproduced.
For glass containers, Krones offers INKpression as an alternative to classic labels. Ink is transferred directly onto the container surface, but not in a traditional printing process. The finished design is separated from the backing material and transferred to the container as a whole, enabling a continuous, adherent graphic.
Beverage can market and high recycling rates
Beverage cans have been gaining in popularity for several years, particularly in the segment of soft drinks and energy drinks that are popular among younger consumer groups. In Europe, beverage cans also exhibit high recycling rates. According to data from Metal Packaging Europe and European Aluminium, more than 76 percent of beverage cans were recycled in 2023 and this rate is increasing. Deposit-return systems play a key role, with countries operating deposit schemes achieving recovery rates of up to 90 percent.
Many beverage producers are currently expanding their can portfolios. Coca-Cola Europacific Partners Germany, for example, is investing in a new canning line at its Halle plant. The line is scheduled to start up in the summer of 2026, when it will supplement two existing lines for filling still beverages into PET bottles. According to the company, the multimillion-euro investment responds to rising demand. In 2023, sales of canned beverages on the German market increased by around 12 percent year-on-year.
The demand for beverages in cans is increasing. Image: Coca-Cola / Uli Deck
Beverage cartons and recycling challenges
Beverage cartons often generate mixed opinions, although they combine several important technological features. They are lightweight, opaque, recyclable and around three quarters of their mass consists of carton fibre. The remaining share is made up of barrier layers that provide product protection and extend shelf life.
According to the German Association of Manufacturers of Carton Packaging for Liquid Foods (Fachverband Kartonverpackung für flüssige Nahrungsmittel, FKN), the carton recycling industry is more advanced than is often assumed. Cartons have been integrated into a functioning recycling system, partly thanks to the activities of Tetra Pak, SIG Combibloc and Elopak and the Palurec recycling plant at the Knapsack chemical park. In Germany, around 36,000 tonnes of plastics and aluminium from beverage cartons are recycled each year.
Despite this progress, the recovery level is still insufficient to meet legal requirements. According to current data from the Central Agency Packaging Register (Zentrale Stelle Verpackungsregister, ZSVR), Germany failed to reach the legally required recycling rate for this packaging category in 2024 for the third consecutive time.
Beverage cartons are often more environmentally friendly than their reputation suggests. Image: FKN
Tethered caps and consumer acceptance
Since mid-2024, single-use beverage packaging must be equipped with tethered caps that remain attached to the package after opening. The aim of this design is to reduce plastic litter and facilitate recycling of all packaging components. However, consumer research indicates significant challenges regarding acceptance of the new solutions.
A study carried out by the Nuremberg Institute for Market Decisions (NIM) shows that most consumers consider tethered caps impractical. Around two thirds of respondents criticised the difficult handling, particularly when drinking directly from the bottle and when pouring. This indicates that, in parallel with the implementation of regulatory solutions, producers will need to further optimise cap ergonomics and communication with end users.
Interpack 2026 as a platform for beverage packaging innovation
From 7 to 13 May 2026, numerous exhibitors from around the world will present technologies for safe, attractive and more sustainable beverage packaging at interpack in Düsseldorf. The trade fair will showcase new designs for lightweight PET and rPET bottles, barrier solutions and labelling systems compliant with recycling requirements, as well as advanced can and beverage carton technologies and alternative packaging marking methods.
Detailed information about the trade fair is available on the event website at www.interpack.de.
