Sonoco pushes paper barriers with Kneipp bath crystal packaging

Overcoming the moisture barrier in fiber packaging

The transition from rigid plastics to fiber-based alternatives in the personal care sector has historically faced a significant technical hurdle: moisture. In a notable development for the packaging industry in 2026, wellness brand Kneipp has successfully launched its limited-edition "Lieblingsmensch" bath crystals in a high-paper-content container developed by Sonoco. This move marks a critical step in applying paperization strategies to highly hygroscopic products.

The new packaging utilizes Sonoco's GreenCan technology, achieving up to 98% paper content. Crucially for the circular economy, approximately 69% of the material in the body and lid consists of recycled paper. The structure is designed to be fully compatible with existing paper recycling streams, addressing the end-of-life concerns that often plague multi-material cosmetic packaging.

The technical challenge of hygroscopic products

Bath salts are notoriously sensitive to humidity. Exposure to moisture can cause the crystals to clump, degrade, or lose their aromatic properties, which is why rigid plastic tubs have been the industry standard for decades. To counter this, the GreenCan applied to Kneipp's product incorporates a specialized 6% barrier protection layer. This minimal but highly effective barrier shields the product from moisture, oxygen, and external contamination while maintaining the structural integrity required for transit and retail display.

Jessica Raich, packaging engineer at Kneipp, noted that the limited edition demonstrates how sustainability, innovation, and premium wellness can successfully intersect. The tactile experience of the paper container also aligns with the premium positioning of the Kneipp brand, proving that sustainable material choices do not necessitate a compromise on consumer experience.

This application in the personal care market builds upon Sonoco's recent successes with the GreenCan format in the food sector. Earlier applications include The Noirmoutier Sea Salt Cooperative's Agri-Éthique labeled sea salt range and Kotányi's spice lines. The expansion into bath and body care in 2026 indicates that packaging converters are increasingly capable of fine-tuning fiber structures to meet the rigorous demands of diverse product categories, reducing overall plastic consumption and shipping weights across supply chains.

The successful application of high-barrier paper containers in the personal care sector signals a definitive maturation of fiber-based technologies, proving that functional performance no longer requires a compromise on material circularity. Will the broader cosmetics industry accelerate its transition away from rigid plastics now that the moisture barrier challenge is being systematically solved? 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