Paperboard technology: packaging solutions for reduced plastic use

Why it's time to rethink conventional packaging solutions

Pre-manufactured plastic or metal containers involve significant logistics efforts, require valuable storage space, and lock manufacturers into specific materials for the long term. Long lead times can limit design flexibility, while alternative packaging materials often compromise barrier performance or manufacturability.

Regulatory initiatives such as the EU Packaging and Packaging Waste Regulation (PPWR) and growing consumer expectations are accelerating the shift toward recyclable packaging. To support flexible production concepts with smaller batch sizes and shorter time-to-market cycles, the industry requires solutions that combine material efficiency with barrier performance while simplifying supply chains.

Paperboard technology: Design flexibility meets product protection

With Paperboard Technology, containers are formed immediately before filling from paperboard blanks or a continuous roll. This enables the creation of cup-shaped packaging and cans in a variety of formats, including round, oval, and square designs. Embossing, viewing windows, and a range of closure options further expand the design and functional possibilities.

The technology does not compromise on product protection. Multi-layer material structures provide barriers against oxygen, moisture, and aroma loss, helping to preserve product quality throughout the entire shelf life. Tight sealing, mechanical stability, and process reliability also ensure seamless integration into modern filling operations.

Cost reduction and greater flexibility with paperboard technology

A major advantage lies in decoupling packaging production from the supply chain. Using flat carton blanks or rolls instead of pre-manufactured containers significantly reduces storage and transportation costs. This also provides greater flexibility, as design changes can be implemented at short notice without waiting for new packaging batches. Inline processes reduce interfaces and simplify planning. Short format changeover times of approximately 20 to 45 minutes enable economical production of smaller batch sizes, while an open material system gives manufacturers greater flexibility in supplier selection.

Bringing paperboard technology into industrial production

The combination of fiber-based material, production flexibility, and lower supply chain complexity positions paperboard as an important technology for next-generation packaging solutions. The technology enables companies to meet regulatory requirements while improving efficiency and responding more quickly to changing market demands.

Optima supports this approach with integrated machine concepts for paperboard processing. The systems enable inline forming directly before the filling process, achieve outputs of up to 150 containers per minute, and can be flexibly integrated into existing production lines. Compact machine designs, short changeover times, and turnkey solutions combine technological innovation with proven industrial practicality.