Masterpress is expanding PFAS-free packaging pouches through a new manufacturing line at its Białystok facility in Poland. Operational since September 2026, the Karlville Swiss machine produces paper-based pouches containing over 90% paper and 95% bio-based materials. These structures provide strong protection against oxygen and moisture, making them suitable for dry foods, pet products, and supplements. The paper material has also passed recyclability assessments, although finished printed pouches require further testing.
The investment allows Masterpress to connect printing and pouch production without additional lamination or curing stages, shortening manufacturing timelines. Brands can explore different packaging formats through smaller trial runs before committing to larger orders. With European packaging regulations placing greater emphasis on recyclability, the expanded capabilities offer manufacturers more flexibility when developing compliant packaging while maintaining product protection and operational efficiency.
Image Credit: Masterpress
What's Driving This Trend
- High-barrier Paper Packaging
- Paper-based pouch formats with oxygen and moisture protection create room for recyclable alternatives to multilayer plastics in food, pet care, and supplement categories.
- Pfas-free Material Reformulation
- The shift away from PFAS in flexible packaging reflects growing demand for safer barrier technologies that align with regulatory pressure and consumer health concerns.
- Small-batch Packaging Trials
- Shorter production workflows and trial-run flexibility give brands a lower-risk path to testing sustainable pouch designs before scaling commercial orders.
Who This Affects Most
- Flexible Packaging
- Recyclable paper-rich structures introduce new competitive dynamics for converters seeking high-performance formats without conventional lamination and curing steps.
- Food and Beverage
- Dry food producers benefit from packaging innovations that preserve shelf life while supporting compliance with emerging European recyclability standards.
- Pet Care
- Moisture-resistant paper pouches present a sustainability-focused packaging option for pet product brands balancing durability, freshness, and environmental claims.
