Mondi ramps up FunctionalBarrier Paper Ultimate to meet growing demand for sustainable high-barrier paper-based packaging

Following its previously announced €16 million investment in state-of-the-art technology at its plant in Solec (Poland) Mondi is ramping up production of this high-performance barrier paper which offers exceptional protection against oxygen, water vapour and grease, with an oxygen transmission rate (OTR) below 0.5 cm³/m²d and water vapor transmission rate (WVTR) below 0.5 g/m²d. According to Mondi’s internal product impact assessments, the solution delivers substantially lower cradle-to-grave CO₂ emissions compared to conventional multi-layer plastic or aluminium-based materials¹.  

As part of the re/cycle portfolio, FunctionalBarrier Paper Ultimate meets Mondi’s internal Path to Circularity Scorecard criteria and is designed for recycling according to the Cepi Recyclability Laboratory Test Method (Version 1 – January 2025) and 4evergreen’s Recycling Evaluation Protocol for recycling mills using conventional processes. As a result, customers benefit from a more sustainable alternative to traditional, non-renewable packaging solutions. 

Intended for high barrier applications, the solution is suitable for packaging instant coffee sticks and pod overwraps, tea sachets, dried food seasonings, muesli or cereal bars and bouillon cubes, among others, and ensures long shelf life and convenience.  

The product complements Mondi’s broad range of FunctionalBarrier Papers, which offers customers a variety of barrier levels to suit their individual product requirements. It can help support brands’ circular economy goals by enabling customers to meet changing regulatory requirements and growing consumer demand for more sustainable packaging. 

Compatible with existing horizontal and vertical form-fill-seal packing lines, the paper-based packaging can be efficiently integrated into existing production processes.

FunctionalBarrier Paper Ultimate is the result of customer-driven innovation. With this solution, we are helping brands to move away from multi-material packaging that is unrecyclable, without compromising on performance. This is another concrete step towards our MAP2030 sustainability commitments of designing circular driven solutions, created by empowered people, and taking action on climate. As of today, 87% of Mondi’s packaging solutions are already reusable, recyclable or compostable.

Dirk Gabriel, COO Consumer Flexibles at Mondi

FunctionalBarrier Paper Ultimate is a paper-based ultra-high barrier solution that offers protection against oxygen, water vapour and grease (with an OTR and WVTR below 0.5), making it a sustainable alternative to conventional unrecyclable multi-layer plastic or aluminum-based structures.

 

Learn more about ultra-high FunctionalBarrier Papers here!

1. The product impact assessment compares conventional high-barrier structures (PAP 60/Alu 6.35/PE 30 and PET 12 / Alu 7 / LDPE 80) with Mondi paper-based FunctionalBarrier Paper Ultimate (90 gsm and 60 gsm) (end-of-life EU27).