The packaging industry has made significant progress toward sustainable, recycle-ready solutions — from mono-material polymer structures and plant-based packaging to advanced recycling technologies. Yet, key challenges remain, particularly in developing recyclable retort packaging for the food and beverage sector. Retort pouches, designed to withstand high-temperature sterilization while keeping food shelf-stable without refrigeration, are traditionally made from multilayer laminates combining PET, aluminum foil, and PP. This complex structure ensures durability and barrier performance but makes recycling nearly impossible.
At K 2025, a major breakthrough was unveiled as Bobst, Brückner, and Mitsui Chemicals introduced the world’s first mono-material, recyclable retort solution with high barrier properties achieved through opaque metallization. The innovation marks a crucial step toward closing one of the biggest gaps in flexible packaging circularity. Nick Copeland, R&D director, barrier solutions at Bobst; Willi Lindemann, specialist inline coating, new technologies at Brückner; and Anrika Heermant, senior specialist at Mitsui Chemicals Europe, shared insights into its development and industry impact.
Can you introduce what the new solution is and why it’s so important?
Nick Copeland: It’s a novel mono-material retort solution with high barrier properties based on special opaque metallization, which will be easily recyclable in existing recycling streams. It’s important because recyclable retort packaging is one of the final key challenges in sustainable flexible packaging. Together, we have achieved a very important milestone, demonstrating that our solution can withstand the retort process and maintain high barrier qualities. Now, if we can take this solution through the final stages of development, it could have a significant impact for the packaging industry and on wider sustainability targets.
Why is it so challenging to develop a recyclable retort solution?
Anrika Heermant: Up until now, it has only been possible to maintain a high barrier in retort solutions using a composite layer structure consisting of polyester, aluminum foil, and various other materials. The most challenging part of producing a mono-material retort solution is maintaining the barrier qualities after the retorting process, which happens under really high temperatures.
Willi Lindemann: The perception in the industry was that it couldn’t be done. It was generally assumed that metalized films could not be used for retort purposes without corrosion, because the high temperatures involved would lead to water ingress. The other challenge with moving to mono-material polypropylene is the risk of shrinkage, which would have a negative impact on the barrier properties. So, there was a lot to contend with.
Can you talk about the innovation involved and how each partner contributed to this success?
Nick Copeland: Ultimately, we needed to create an ultra-thin, stretchable, heat-resistant barrier primer in combination with advanced opaque metallization. When we talk about in-line coated ultra-thin layers and state-of-the-art extrusion and orientation technology, that is exactly what Brückner can bring to the table. When it comes to advanced metallization, Bobst has significant expertise in this area. And Mitsui has the capabilities and innovation to be able to develop a novel heat-resistant primer. So together, we had exactly the right expertise to develop this solution.
Willi Lindemann: Brückner was responsible for the inline coating technology. We know that achieving a very thin metal receptive layer can be the key to sustainable barrier packaging. Through our innovative technology, we can stretch the primers and create very thin layers. We needed to find exactly the right hardness of the coating material to ensure it was both stretchable and could withstand the retort conditions. Ultimately, we found a solution with ideal structure.
Nick Copeland: The reels produced by Brückner in Germany on the inline coating pilot line were then delivered to Manchester in the UK for Bobst’s vacuum coating technology. We utilized the Bobst EXPERT K5 vacuum metallizer with AluBond technology, which is a novel vacuum metallizing technology with three key benefits – it improves the barrier, improves the adhesion, and maintains the surface energy over time. So, the combination of the extremely thin inline coating together with extremely thin metallization achieves the high barrier performance, but on really thin layers, maximizing the percentage of mono-material in the structure. It was also very beneficial being able to test the inline-coated metallized material in our Competence Center in Manchester with our process experts available on hand.
Anrika Heermant: At Mitsui, we contributed two key materials to the solution. The first is a water-based polyurethane dispersion called TAKELAC. We provided a top coating grade, which enhances the barrier performance and protects the Alubond layer. And a newly developed TAKELA Primer grade, which provides the heat resistance suitable for retort applications. In addition, we provide ADMER, which is a grafted polyolefin resin with good adhesion qualities.
How effective is the new solution?
Anrika Heermant: We have achieved proof of concept. We have demonstrated that by combining inline coating, vacuum metallization and special resins and coatings, we can create a recyclable solution that withstands the retort process and maintains its barrier qualities. We’ve tested the Oxygen Transmission Rate (OTR), the Water Vapor Transmission Rate (WVTR) and adhesion levels before and after the retort process and achieved excellent results.
Is the new solution ready to use? What kind of products will it be suitable for?
Willi Lindemann: While we have achieved a huge milestone, we haven’t finished the development of the solution yet. There’s still some work to do before this solution can become commercially available. But we are well on the right road. The next step may be to bring in further partners to ensure the solution is robust, repeatable, and production proof.
In terms of the type of food this solution could be used for, it’s really any retort food – that is, food that is sterilized within the packaging. A good example is wet pet food.
What impact could this have on the industry?
Anrika Heermant: It’s too early to speculate on the potential impact, but there is no question that the industry needs solutions like this. Companies will need to comply with sustainability guidelines such as the Packaging and Packaging Waste Regulation, meaning for example that mixed materials will no longer be permissible for wet pet food in the retail setting. So, we are aiming to fulfil an urgent unmet need.
Why has this partnership worked so well?
Nick Copeland: It’s exactly the right combination of expertise and each company is really the leader in their respective fields, which makes it a very pioneering initiative and one where there is full trust and respect on all sides.
Each company also has all the required elements to help make this happen, meaning well- equipped laboratories, technology centers or Competence Centers, and dedicated process experts which has made accelerating the development of this solution providing faster time to market.
I know I speak on behalf of the entire team when I say that we’re eager to keep pushing boundaries together and look forward to showcasing what’s next.
