Reliably Printing Paper Sleeves with a Focus on Recyclability
Case Study
Challenge
A consumer goods manufacturer wanted to improve its product packaging in terms of material usage and recyclability while also meeting the rising expectations of retailers and end customers for more environmentally friendly packaging. The plastic solutions previously used were to be replaced by a paper sleeve designed for recyclability.
However, one key factor could not be compromised: reliable product labeling. Barcodes, lot numbers, and product information must be applied quickly, cleanly, and with permanent readability during the production process.
This was precisely where the challenge lay. In thermal transfer printing, paper-based materials are considered more challenging than smooth plastic surfaces. The natural texture of the paper can lead to uneven print images or reduced barcode readability.
The customer was therefore looking for a solution that met three requirements simultaneously:
- Paper-based packaging
- Reliable marking with thermal transfer printing
- Seamless integration into existing production processes
Solution
For the packaging designed for improved recyclability, the customer relied on the heat-sealable paper sleeve Koehler NexPlus® Seal Bundle from Koehler Paper. For marking, the K 7 EVO thermal transfer ribbon from KURZ was used, which was specifically developed for reliable printing results on various substrates. Tests showed that the ribbon enabled clear, high-contrast, and permanently legible printing even on the paper-based surface. This allowed the paper-based packaging solution to be successfully combined with existing thermal transfer printing technology.
The solution impressed with:
- Reliable print quality on paper bands
- Excellent barcode and Data Matrix readability
- High process reliability in thermal transfer printing
- Food-safe materials
- Recyclable packaging solution
This enabled the customer to switch their packaging to paper bands with a focus on recyclability without having to forego proven printing technology.
Implementation
A key advantage of the solution was its easy integration into existing production lines. The paper bands made from Koehler NexPlus® Seal Bundle were used in the packaging process, while labeling continued to be performed using thermal transfer printing and the K 7 EVO ribbon. The existing printing systems could continue to be used without major modifications. Printing parameters and production speeds remained comparable.
It became apparent even during the test phase that the customer could achieve:
- Consistent print quality even on paper surfaces
- Clean contours for text, logos, and barcodes
- Reliable barcode readability during operation
The transition to paper-based bands therefore went smoothly.
Results
After implementing the new solution, the customer was able to realize several benefits:
- Successful transition to paper packaging
- Reliable labeling with thermal transfer printing on paper
- Stable printing processes without major production adjustments
- Improved product perception thanks to a natural packaging look
Especially in retail, the paper bands helped create a visible point of differentiation on the shelf. At the same time, the packaging solution supports the company’s sustainability strategy.
Conclusion
The combination of the Koehler NexPlus® Seal Bundle and the KURZ K 7 EVO thermal transfer ribbon demonstrated that paper packaging designed for recyclability and reliable labeling could be very effectively integrated in this specific application. Depending on the application, companies can switch to paper-based packaging solutions and continue to benefit from the efficiency and quality of thermal transfer printing - often without having to fundamentally adjust existing production processes.
Please feel free to contact us for more information on thermal transfer printing on paper and other packaging solutions.
