Mondi, a global producer of packaging and paper, has partnered with Polish dry seasoning manufacturer Prymat to develop paper packaging that supports circular economy goals while providing protection for aromatic spices. As a result of the partnership, Prymat is switching to a new paper-based packaging solution based on FunctionalBarrier Paper Ultimate.
The new packaging is based on a high barrier paper designed as an alternative to conventional multilayer structures made of plastics or aluminium, which are typically non-recyclable. The choice of this solution was preceded by extensive trials and tests intended to confirm its suitability as a more sustainable replacement while maintaining the required protective properties for spices.
According to an assessment conducted using Mondi's product impact analysis tool, FunctionalBarrier Paper Ultimate has a significantly lower impact on CO2 emissions compared to conventional multilayer structures made of plastics or containing aluminium. The material contains at least 80% high-quality paper and a barrier coating optimised for recycling. It has been confirmed as recyclable according to the latest CEPI laboratory recyclability test method, which helps keep valuable raw materials in circulation.
FunctionalBarrier Paper Ultimate provides long-lasting protection against oxygen, water vapour and grease. The declared oxygen transmission rate (OTR) is below 0.5 cm3/m2d, while the water vapour transmission rate (WVTR) is below 0.5 g/m2d. These parameters are crucial for maintaining the aroma and taste of spices throughout storage and distribution.
In addition to its barrier performance, Mondi's paper enables high print quality, which allows Prymat's spice range to be presented attractively on the retail shelf. Another important functional aspect is the material's stiffness, which ensures a so-called dead fold. This allows the consumer to fold the pack after first opening it to close it, with the crease retaining its shape without the need for additional closure elements.
Adaptation to existing filling lines
The new packaging has been designed to be compatible with the existing filling lines at Prymat's facilities. Integrating the solution does not require investment in new machinery, enabling the seasoning producer to pursue its sustainability targets while maintaining continuity and efficiency of production processes.
The need for an individual approach to each customer's requirements when designing packaging structures is also emphasised. Adrian Goralski, managing director of Mondi Solec, comments: "It is essential to understand the individual needs of each customer when creating packaging solutions. There are often several different routes to sustainability, and at Mondi, we work closely with brands to thoroughly learn about every step of their production, distribution and end use. This allows us to create and test various options and be sure that we are delivering the best possible and most sustainable solution."
Barrier challenges for spices
Replacing traditional plastic-aluminium multilayer laminates with paper-based structures is a major technological challenge, particularly in the spice segment, where very high barrier parameters are required. Spices are sensitive to oxygen, moisture and fat, and their quality is closely linked to maintaining aroma and freshness throughout shelf life.
The spice producer also draws attention to these requirements. Marta Klęka-Nowa, PR manager at Prymat, notes: "As a leading producer of spices and food additives, Prymat has consistently sought solutions to transition from multi-layer packaging to recyclable materials. Given the very high barrier requirements and the need to preserve the quality, aroma and freshness of spices, this posed a significant technological challenge. Thanks to our collaboration with Mondi, we were able to develop a solution that aligns our sustainability ambitions with the highest standards of product quality.
Working with Mondi was such a valuable experience, we truly became one team working together towards a shared goal."
The implementation of FunctionalBarrier Paper Ultimate in Prymat's spice packaging is part of a broader trend of replacing non-recyclable plastic-aluminium laminates with paper-based solutions that combine barrier functionality with compatibility with existing fibre recycling systems.
Mondi paper barrier packaging for Prymat spices
