STADLER’s Vision of Unlocking the Untapped Potential of Paper Recycling

The demand for sustainable packaging solutions has reached unprecedented levels, especially in the food industry, where consumers are increasingly drawn to environmentally responsible products. This shift has accelerated the adoption of paper-based packaging, driven by both market dynamics and regulatory requirements. The global paper packaging market is experiencing rapid growth, with projections estimating it will reach USD 97.6 billion in Europe and USD 75.64 billion in North America by 2025, with respective compound annual growth rates (CAGR) of 4.8% and 3.9% by 2030. Leading this transformation, the food industry is seeing a surge in liquid cartons, one of the fastest-growing packaging formats, propelled by sustainability commitments and consumer preferences. However, despite its potential, paper packaging presents challenges—particularly when it comes to recycling.

Despite the widespread adoption of paper-based solutions, a significant portion of paper—particularly from mixed waste streams—still goes unrecycled. Research indicates that in Germany alone, lightweight packaging waste could yield approximately 100,000 tons of high-quality paper annually, a resource that remains largely underutilized due to persistent challenges. The EnEWA project, a collaboration between STADLER Anlagenbau GmbH, academic institutions, and industry leaders, has made notable progress in proving the technical viability of recycling paper from mixed waste. However, regulatory barriers continue to hinder the full realization of this potential.

The Rising Challenge of Paper-based Packaging

The food industry is witnessing a remarkable shift towards paper packaging, driven by both environmental concerns and consumer demand. Companies are heavily investing in sustainable paper solutions, with innovations such as Pulpex’s paper bottles made from sustainably sourced wood pulp highlighting the industry’s commitment to reducing environmental footprints. Despite these advancements, recycling paper, particularly from composite packaging, remains a complex issue.

Composite packaging, often used in food products, combines multiple layers of materials like paper, plastic, and aluminium. These layers are difficult to separate, making the recycling process energy-intensive and prone to contamination. Also, some of the new composite packages can be confusing for consumers, as they may appear to be entirely made of paper but contain layers of other materials. While technological advancements have shown promise, the regulatory environment poses significant hurdles.

The Regulatory Hurdle

The regulatory landscape is designed to ensure the safety and quality of recycled materials used in food contact applications, though approaches vary. EU regulations are prescriptive, requiring detailed testing, documentation, and often pre-market authorisation, reflecting a precautionary approach to ensure consumer safety. Germany’s BfR Recommendation XXXVI, although officially a guideline, imposes strict criteria to minimise contamination risks, effectively restricting the use of recycling paper from mixed streams for food applications, influencing industry practices and contractual agreements. 

Regulations in other EU countries, such as Italy and Spain, are less prescriptive but still demand a high level of scrutiny on the sources of recycled fibres, posing challenges for using mixed waste paper in food packaging, reflecting a broader European commitment to maintaining safety in recycled materials. Scandinavian nations comply with EU regulations while adding national guidelines to address specific regional concerns, ensuring high consumer safety. North American regulations, on the other hand, focus more on general safety and good manufacturing practices, allowing more flexibility but placing greater responsibility on manufacturers to ensure compliance.

“The EnEWA project has shown that with the right technological adjustments, such as improved sorting and sanitisation processes, high-quality paper can be recycled from mixed waste streams,” explains Annika Ludes, Product Engineer at STADLER. “However, to fully realize this potential, changes in the regulatory landscape are essential. Amendments to guidelines like the BfR Recommendation XXXVI could pave the way for more sustainable use of recycled paper in the food industry.”

The EnEWA Project’s Contributions

The EnEWA project has provided compelling evidence that recycling paper from mixed waste is technically feasible. The project demonstrated that through innovative sorting technologies and adapted processes with dry-mechanical sorting, wet processing, and sanitization, secondary fibres could be obtained and used in paper production without significant contamination issues. Special sorting technologies, like Near-Infrared (NIR) sensors, were optimised to identify and separate composites. Additionally, processes like hot dispersion under overpressure proved successful in reducing microbiological contamination.

Beyond technological advancements, the EnEWA project has engaged with regulatory authorities, advocating for updates to waste management guidelines and amendments to restrictive regulations. It has developed recommendations towards a more flexible regulatory approach, especially for applications outside the food sector or for dry food packaging, backed by scientific data from worst-case scenario experiments. The project has also held workshops involving representatives from stakeholders including the packaging industry, sorting facility operators and paper recyclers.

The Future of Paper Recycling

While the EnEWA project has concluded, its legacy continues. STADLER, now an associated partner in the SPaRe project, is working to further enhance the energy efficiency of the paper recycling cycle. This initiative aims to optimise the utilisation of residual materials in paper production, potentially saving 1 TWh of energy annually – equivalent to 1.6% of the annual energy consumption of the paper industry – and reducing greenhouse gas emissions by approximately 350,000 tons of CO₂ equivalents per year.

The EnEWA project has put the spotlight on the untapped potential of paper recycling, showing that the technology exists to recycle significant amounts of paper from mixed waste. However, unlocking this potential requires a concerted effort to overcome regulatory barriers and improve waste management practices. By addressing these challenges, we can turn what is currently a lost resource into a cornerstone of sustainable packaging, driving the industry towards a more circular and environmentally friendly future.

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