Mondi: Networking along the value chain

The packaging and paper company Mondi offers customised solutions for primary and secondary packaging. The manufacturer's integrated value chain enables a comprehensive exchange of expertise between the business units, which ultimately benefits the customer.

In common parlance, the term packaging is used for everything in which products are sold. In the case of foodstuffs, however, food law distinguishes between Primary and Secondary packaging. The former includes materials that come into direct contact with the food or beverage, while secondary packaging has no direct contact with the product. Whether primary or secondary packaging - as a fully integrated packaging and paper manufacturer, Mondi controls the entire value chain: All processes from material extraction and paper production to packaging production, printing, lamination and packaging can be carried out across all segments within the Group. This enables the company to react quickly to the current market situation or customer requirements and realise short throughput times.

Benefit from synergies

Mondi Corrugated Packaging, a business segment of the Europe & International Division, produces corrugated packaging and has particular expertise in the area of shelf-ready secondary packaging. Thanks to its close links with Mondi Containerboard and Mondi Extrusion Coatings, the company is able to utilise the majority of its corrugated base paper internally, We use innovative extrusion coatings to ensure a cost-efficient supply of high-quality materials. For example, paraffin-free, water-repellent fruit and vegetable crates with speciality papers, bag-in-box concepts for wine and juice packaging or corrugated board packaging with a functional barrier layer.

Solutions for primary packaging

Food packaging must reliably protect its contents from external influences, as flavour and consistency must be retained. The possible transfer of undesirable substances such as aromatic and saturated mineral oil hydrocarbons (MOSH: Mineral Oil Saturated Hydrocarbons, MOAH: Mineral Oil Aromatic Hydrocarbons) from the packaging into the product poses a challenge for the food industry. Mineral oils are suspected of being harmful to health. German legislation is currently discussing a proposal to amend the Consumer Goods Ordinance. This recommends a specific labelling requirement as soon as recycled, fibre-based packaging material is used.

With the Miprotex® barrier coating Mondi Extrusion Coatings is already responding to potentially stricter regulations. The special coating Prevents mineral oil migration and also shields flavours, fats, oxygen and water vapour. It is certified for direct food contact and can be used, for example, in paper-based primary packaging for baking mixes, sugar, rice, pasta or pizza boxes as well as in secondary or transport packaging. Miprotex® is also a cost-effective alternative to conventional barrier solutions such as aluminium.

For sustainability reasons, many food manufacturers are no longer using aluminium as a barrier layer, but are looking for alternatives. BarrierFilm from Mondi Extrusion Coatings is based on paper, polyethylene and a special barrier that protects the contents and ensures a long shelf life. In this way, the aluminium-free paper laminate prevents the loss of flavour in coffee, tea, spices or instant soups. It also enables food manufacturers to reduce the carbon footprint of their packaging.

Barriers for secondary packaging

Manufacturers who also use a standardised packaging for their secondary environmentally friendly barrier layer can search for Paratén® or Paratherm® to fall back on. These are wax-free and therefore easily recyclable. As the polymer coatings are also water-resistant, they score particularly well in corrugated board packaging that contains frozen goods or in which fruit and vegetables are stored in high humidity. In addition, corrugated cardboard packaging with Paratén ® or Paratherm® can replace airpop boxes when transporting fish: They are more durable, save space and can be recycled.

Ralph Köhler, Team Leader Innovation, Design & Preparation Tools at Mondi Corrugated Packaging in Bad Rappenau knows: „A good packaging design not only optimally protects the contents, but also correlates with the primary packaging. This is the only way to achieve a uniform appearance on the shelf.“

More than just transport packaging

The increasing demand for „Shelf-ready packaging“ is changing the role of secondary packaging. Retailers need to fill their shelves in a time-saving manner and utilise sales space efficiently. As a result, more and more secondary packaging is moving directly from the pallet to the shelf and therefore needs to be Visually appealing and Easy to handle be. It starts with the weight.

With a wide range of flute profiles, Mondi can achieve the same packaging performance despite using less material and thus produce lighter packaging. For fruit and vegetable trays, for example, fine flute can be used instead of heavy solid board, thus saving up to 35 per cent material. For example, corrugated cardboard weighing just 800 g/m2 can be used instead of solid cardboard weighing 1,200 g/m2. This gives manufacturers a cost advantage, while retailers benefit from lower packaging weight and reduced waste.

Food and beverage manufacturers are also looking for solutions that are suitable as a marketing tool, as the products must immediately catch the consumer's eye on the shelf. According to the Shopper Engagement Study, almost 80 per cent of customers buy spontaneously and are motivated by visual aspects. Whether wraparounds, folding cartons with perforations, displays or „tray and hood“ constructions, the trend is increasingly moving towards high-quality printing and multi-colours as well as die-cut packaging. The high level of complexity involved in the development of die-cut products is a challenge for packaging designers.

Ralph Köhler emphasises: „As we coordinate very well internally with the Consumer Goods Packaging division, for example, and can draw on its expertise, primary and secondary packaging at Mondi are created from a single mould.“

All-round service in demand

With additional services such as printing, gluing and warehouse management, Mondi Corrugated Packaging offers customers a comprehensive service. The packaging manufacturer can respond quickly to individual requests as it can draw on a wealth of inspiring designs and is constantly developing its products. With the help of professional planning tools corrugated board qualities, material consumption and pallet capacities can be optimised and the desired print variants and components such as polymer barriers can be selected for the packaging.