Saica eliminates reel packaging waste with linerless repulpable paper tape

Every paper mill manager and corrugator operator knows the operational friction caused by tape residues in the pulping process. Adhesive tapes and synthetic bands, despite comprising a microscopic fraction of a reel’s total weight, historically create outsized problems. They can cause screen blockages, introduce sticky contaminants into the system, and ultimately lead to quality defects in the final recycled board. Earlier in 2026, Saica Group took a definitive step to eliminate this bottleneck by launching the market's first fully repulpable, recycled paper adhesive tape.

The development is a direct result of cross-divisional synergy between Saica Paper and Saica Flex. By combining raw material production with converting expertise, the multinational company has engineered a product that strips away non-essential components. The new tape is entirely linerless, meaning it requires no silicone release liners or separating elements that typically complicate recycling streams.

Perfect Circularity in Reel Packaging

What makes this development particularly relevant for the broader paper packaging industry is its closed-loop architecture. The tape is manufactured using 100% recycled fibers produced within Saica’s own mill network. Saica Flex then converts this substrate into a highly durable self-adhesive format. Finally, the tape is deployed to band and protect the very same paper reels from which its base fibers originated.

When the corrugated plant receives the reel and eventually pulps the waste and trim, the tape dissolves seamlessly back into the fiber matrix, ensuring maximum recovery yield without degrading the secondary raw material.

Backward Compatibility Without CAPEX

A common hurdle for new sustainable packaging materials is the capital expenditure required to adapt existing machinery. Saica circumvented this barrier by engineering the tape to be entirely backward-compatible. Technical implementation data confirms that the linerless solution integrates flawlessly into standard reel-wrapping machines.

It unwinds smoothly, overlaps securely, and adheres firmly to paper and cardboard without requiring any equipment modifications or fresh investments at the plant level. This plug-and-play approach significantly accelerates its adoption curve across industrial environments.

Market Impact and Rollout in 2026

The operational rollout is already underway. The tape has been successfully implemented at Saica Paper’s massive El Burgo de Ebro facility in Zaragoza, Spain. Throughout the remainder of 2026, the group plans to deploy the system across its other European paper production lines.

Federico Asensio, Technology & Innovation Director at Saica Group, indicated earlier this year that reel packaging is merely the proving ground. His R&D teams are actively researching new commercial applications for the technology, aiming to expand Saica Flex’s portfolio of sustainable solutions. As converters and fast-moving consumer goods (FMCG) brands navigate the stringent Design for Recycling (DfR) guidelines imposed by evolving European regulations, eliminating hidden contaminants is paramount. A completely repulpable tape stops being a niche environmental upgrade and becomes a tangible operational asset.

This internally developed, liner-free tape proves that the most effective industrial innovations do not always require replacing the machine, but rather fundamentally rethinking the material itself. Will this fully repulpable standard eventually force conventional synthetic tapes out of the corrugated logistics chain entirely? 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