Syntegon Technology, formerly Bosch Packaging Technology, and BillerudKorsnäs have developed a system that allows shapes of any kind to be formed from paper for various food and non-food applications.

Syntegon's new TPU paper form, fill and seal machine forms what the partnership describes as “environmentally friendly” shaped paper pods with a filling volume of up to 100 milliliters.

The machine shapes BillerudKorsnäs' FibreForm paper using air pressure, before embossing it via press force. Using heat-sealing technology, Syntegon and BillerudKorsnäs say that their shaped paper pods can be sealed with any heat-sealable lidding materials, and that barriers will be completely customized to customer needs.

“FibreForm is a natural alternative where plastic has been the norm. This allows for up to ten times deeper embossing than regular paper, resulting in 3D effects that make an impact,” comments Simon Johansson, Project Manager at BillerudKorsnäs, Sweden.

To showcase the possibilities of the system, Syntegon Technology and BillerudKorsnäs have previously presented the packaging concept "Pearl”. As of now, the partnership claims that shapes of any kind can be formed for various applications.

The companies say that their new solution is ideal for product samples, inserts, refills, and disposable packaging. They are also positioning the new system as an ideal solution for individual portion packs and products that would usually be packed in blisters. In addition to cosmetics or samples, shaped paper pods can apparently be used to package dry, chunky, or viscous food thanks to a thin barrier layer. The new TPU paper forming machine also reportedly offers manufacturers a range of filling and sealing systems for sustainable packaging at an output of up to 15,000 Shaped Paper Pods per hour.

“We achieved a perfect match of technology and material for scalable packaging solutions, which creates a unique sensory experience for brand and customer interactions,” says Matthias Klauser, Sustainability Expert at Syntegon Technology, Germany.