Large Baltic converter: paper-like film instead of a paper, aluminium, PE laminate

A large laminate converter from the Baltic region, supplying packaging for butter and cheese, wanted to move away from a paper, aluminium, PE laminate without losing the paper look, the grease barrier and the ability to wrap the product into blocks. A single paper-like film with chalk, 55 µm as standard, replaced three laminate layers: no aluminium and no paper.

01 Customer

Baltic region. A large laminate converter, food packaging: butter and cheese. The customer had historically specialised in paper plus aluminium plus PE laminates.

02 Challenge

The customer wanted to simplify the pack construction and move away from aluminium, but had to keep everything the laminate provided: the paper look, the grease barrier and the ability to wrap the product into blocks.

Removing aluminium usually means losing the barrier.

03 Solution

• Base: a PE-based paper-like film.
• Composition: a high share of mineral components (chalk) and a share of bio-based raw materials.
• Thickness: adapted to the customer’s block-wrapping process, 55 µm as standard.
• Construction: one film instead of three laminate layers, no aluminium and no paper; the high mineral content reduces the amount of polymer in the pack.

04 Results

Before and after

Pack construction	paper, aluminium, PE laminate (three layers) → one paper-like film
Aluminium	aluminium layer → no aluminium, grease barrier retained
Look and block wrapping	paper look and shape memory for block wrapping retained
Thickness	target 55 µm
Polymer in the pack	less, thanks to the high mineral content

05 What this means for you

An aluminium laminate is convenient technically, but it means three materials in one pack. If you pack butter, cheese or fats and want to simplify your pack structure, this is a route that does not require changing your packing machine.