Koehler Paper scales its NexPlus Seal Pure flowpack in Bel Group lines without speed losses
Bel Group has adopted Koehler Paper's NexPlus Seal Pure for its Babybel 2 Go flowpacks, achieving a full transition to recyclable virgin fiber without sacrificing packaging line speeds.
Overcoming the machinability bottleneck in flexible paper packaging
The transition from flexible plastics to paper in high-volume FMCG lines frequently encounters a critical bottleneck during the forming and sealing stages. Koehler Paper and Bel Group have bypassed this hurdle with the commercial rollout of a recyclable paper flowpack for the Babybel 2 Go snack range. The new packaging utilizes Koehler NexPlus Seal Pure, a material composed of 100% virgin fiber pulp that directly replaces the biobased plastic film Bel introduced in 2020.
The industrial significance of this deployment lies in its converting compatibility. According to operational data, the NexPlus Seal Pure substrate processes on Bel Group's existing packaging lines at speeds comparable to conventional polymer films. This is largely achieved through the paper's low-temperature heat-sealing capabilities, which ensure barrier integrity and secure closures without causing thermal degradation to the fiber network during rapid machine cycles.
Structural stability eliminates secondary packaging
Beyond matching the throughput of plastic films, the mechanical properties of the Koehler substrate have yielded unexpected material savings. The inherent structural stability of the virgin fiber paper allowed Bel Group to completely eliminate an additional inner cardboard packaging layer that was previously required, streamlining the overall packaging architecture and reducing the total material footprint per unit.
The paper flowpack is currently available in the United States, Canada, and select European markets, aligning with Bel Group's strategic target to transition 100% of its Mini Babybel portfolio to responsibly sourced paper by 2027. For Koehler Paper, this commercial application validates its recent investments in real-world testing infrastructure, including the installation of Rovema vertical form-fill-seal equipment at its Oberkirch facility to optimize barrier papers for high-speed industrial converting.
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