In a groundbreaking move for the frozen food industry, Italian frozen pizza brand Pizza A Mano, based in South Tyrol, has adopted Koehler Paper’s heat-sealable paper technology for its packaging. This initiative, showcased at drupa 2024 in Düsseldorf, Germany, aims to bring easy re-cyclability to the freezer aisle, a space traditionally dominated by plastic packaging.
Pizza A Mano’s new packaging, currently available in Austrian supermarkets, marks a significant departure from the norm. Yevgen Zolotkovski, sales director of flexible packaging paper at Koehler, emphasized that this development aligns with a broader industry trend towards sustainable packaging for confectionaries salty snacks, and deep-frozen foods.
“The industry is moving towards more sustainable packaging solutions, and our sealable paper technology is at the forefront of this shift,” Zolotkovski said. The NexPlus Seal paper technology not only replaces the typical plastic shrink film but also eliminates the need for secondary packaging cartons. This innovation reduces material usage and simplifies the packaging process.
The paper’s heat-sealable function runs efficiently on horizontal flow-wrap packaging equipment. “The brand uses just one layer of our mono-material flexible packaging paper with a heat-sealable function, which is all they need for this product,” explained Zolotkovski. Since the pizza remains deep-frozen until it reaches the consumer’s kitchen, the packaging does not require additional barrier properties. The paper offers sufficient resistance to light humidity for the journey home, protecting the product from condensation as it begins to thaw.
“This paper provides enough resistance against internal humidity for a short period,” noted Zolotkovski, ensuring that the pizza remains protected until it is ready to be baked. One of the primary advantages of Koehler’s sealable paper technology is its recyclability. Unlike plastic, which often faces low recycling rates due to insufficient capacity, paper enjoys a high recycling rate. “The difference between recyclable in theory and practice is the difference between plastic and paper,” Zolotkovski said. “For paper, we have a very high recycling rate.”
Koehler encourages brands using its paper technology to clearly communicate its recyclability to consumers. “It’s up to the brand owner, but many are eager to inform customers about the recyclability of our paper, which is 100% paper and curbside recyclable,” Zolotkovski added.
While Pizza A Mano is the first to use Koehler’s sealable paper for frozen pizza, other brands have also adopted this technology. Chocolate start-up nucao, for instance, switched to Koehler’s NexPlus Advanced barrier paper for all its packaging in late 2022. This paper offers high grease resistance, an oxygen barrier for products containing nuts or dried fruits, and a mineral oil barrier, making it ideal for chocolate packaging.
Tea packaging is another area where Koehler’s paper technology is making significant strides. The paper fulfills consumer demands for sustainability, offering various solutions for loose tea, single-packed tea bags, and associated products like sugar. “Most brands have realized that tea and plastic don’t fit, and consumers don’t accept it anymore,” Zolotkovski said.
One common concern among brand owners is the cost and complexity of switching from plastic to paper packaging. Koehler Paper addresses these concerns by offering support and expertise throughout the transition process. “We sometimes hear fears that switching to paper requires significant investments in new machinery, but this is not a major issue,” said Alex Stöckle, corporate director of marketing and communications at Koehler. “Small investments in fixtures and temperature adjustments are often all that’s needed.”
For older machinery nearing replacement, the switch might be more challenging. However, many new machines can handle both plastic and paper packaging. Koehler works closely with machine manufacturers to ensure compatibility and offers “paper packs” to retrofit older equipment.
Pizza A Mano’s switch to Koehler Paper’s heat-sealable paper packaging represents a significant step towards sustainable innovation in the frozen food industry. By simplifying the transition and maintaining product integrity, Koehler is enabling more brands to adopt recyclable packaging solutions, thus reducing environmental impact and meeting consumer demands for sustainability.