Masterpress internalizes paper pouch production with new Karlville line in Poland

The flexible packaging sector is undergoing a brutal rationalization. Converters can no longer afford fragmented supply chains if they want to meet the aggressive timelines of the EU Packaging and Packaging Waste Regulation (PPWR). Masterpress has read the market signals clearly. By installing a new Karlville Swiss pouch-making line at its Białystok facility this July 2026, the European converter is pulling a critical step of the value chain in-house, directly connecting its digital and flexographic printing capabilities with pouch converting.

Mastering the paper transition

This investment is not merely about adding capacity; it is a calculated move to master the material transition. The industry knows that converting paper-based structures is notoriously difficult compared to traditional multi-layer plastics. Paper lacks the inherent elasticity and sealing properties of polymers. To address this, the new Karlville Swiss machine is equipped with eight independently controlled servo motors. This setup allows operators to precisely manage web tension across the feeding, sealing, cooling, and cutting stations, a non-negotiable requirement when handling delicate substrates.

The technical output of this line directly targets the current demands of fast-moving consumer goods (FMCG) brands. Masterpress is now capable of producing pouches with over 90% paper content, alongside high-barrier and PFAS-free solutions. The elimination of per- and polyfluoroalkyl substances (PFAS) is particularly relevant in 2026, as regulatory scrutiny over these forever chemicals has forced brands to seek alternative barrier coatings that do not compromise grease and moisture resistance.

Single-layer structures and operational efficiency

Beyond paper, the Białystok facility is leveraging the new equipment to process recyclable single-layer polyethylene (PE) structures. Mono-material packaging remains the most viable route for plastic circularity, but it requires highly accurate temperature control during the sealing phase to prevent film distortion. The Karlville line provides this precision while maintaining an exceptionally low energy footprint, consuming only 5 to 7 kilowatt-hours (kWh) during operation.

From a supply chain perspective, bringing pouch production in-house eliminates the need to ship printed reels to external converters. This consolidation drastically reduces lead times and minimizes the carbon footprint associated with transportation. For brand owners, it means faster commercial trials and a more agile response to market shifts, without the burden of ordering massive minimum quantities.

Masterpress is demonstrating that the future of packaging conversion relies on tight integration. By controlling the entire process from printing to the final pouch formation, the company is positioning itself as a single-source provider for brands scrambling to meet their 2030 sustainability targets.

The internalization of converting processes by mid-sized players like Masterpress signals a structural shift where agility and material expertise outweigh sheer volume. Will the traditional separation between printers and pouch converters survive the decade as more companies opt for end-to-end in-house production? Follow The Paper for daily news, market signals and key updates from the global paper, corrugated and packaging industry. — Sigue toda la actualidad del sector en www.thepaper.ai