As pressure from consumers and regulators intensifies, the packaging industry is accelerating its shift toward more sustainable, recyclable, and resource-efficient solutions. Schubert, a leading manufacturer of modular, digital, and robot-based packaging machines, is responding with innovative technologies designed to meet environmental goals without compromising profitability or performance.
“Sustainability and recycling are more in demand among consumers than ever before,” the company states. With “71 per cent of US consumers over the age of 21 willing to choose the sustainable option over a similarly priced product” and similar trends observed in Finland, where “more than one in three respondents said they would be willing to spend a little more for more sustainable packaging,” the industry faces both a challenge and an opportunity.
In Germany alone, “several million tons of packaging waste are generated every year,” underscoring the need for change. Schubert’s innovations aim to “develop more environmentally friendly packaging solutions, conserve resources and produce more efficiently.”
Glueless Cardboard Packaging with Dotlock
One breakthrough is Dotlock technology, which “enables glueless cardboard packaging.” Traditional glued cardboard packaging is “not entirely recyclable due to the glue used to seal the cardboard packaging,” which is also energy-intensive and requires heating.
With Dotlock, “several layers of cardboard can be joined completely glue-free by reshaping them, similar to clinching metal.” A needle pierces the cardboard, creating “a collar on the other side,” which is then pressed back to form a “stable force and form fit.” Schubert confirms that this method achieves “the same strength as with a glued connection,” with the key advantage being “that the mono-material cardboard packaging is fully recyclable.”
This approach offers a “fully recyclable” solution that allows companies to “save resources and strengthen their image as an environmentally friendly company wherever solid cardboard packaging is used.”
Flow-Wrapping for Recyclable Films
Plastic films, valued for their barrier properties, remain essential in many applications. But recyclability is key. Schubert highlights that “monofilms, which consist of a single plastic, are the most easily recyclable,” though their “lower melting point” poses challenges during sealing.
Schubert’s Flowpacker series addresses this with “Box Motion sealing technology,” allowing the use of “recyclable flowpacks made from monofilms and even paper-based films.” The system uses a “gentle ultrasonic sealing process” that’s ideal for “polymers with a low melting point and do not require heat protection.”
Flexibility is also central to sustainability. The company notes that manufacturers often need to “switch between different sealing technologies, product formats and packaging materials.” Flowpackers are built to accommodate this diversity. “The use of more sustainable materials, such as bioplastics, is also possible in the same machine,” with changeovers made easy via “different sealing units [that] can be exchanged easily and quickly.”
Schubert explains that the “packaging machine’s modular design makes it a cost-effective option for customers – and makes the use of sustainable packaging solutions even more attractive.”
Reducing Material Through Precision
Reducing packaging size also has a significant ecological and financial impact. “Saving a few millimetres per packaging unit can lead to significant material savings overall – from which the manufacturer benefits economically while conserving natural resources.” The company’s pick & place robots enable this by “placing confectionery products such as bars or pralines with millimetre precision,” while operating “significantly faster and more precisely than humans.”
A Modular Path to Sustainability
Schubert emphasizes that “a firm commitment to sustainability and the conservation of valuable resources are compelling reasons for companies to make their packaging and processes more sustainable.” By adopting “modular packaging machines, versatile robotics and innovative packaging materials,” manufacturers can meet both regulatory requirements and rising consumer expectations.
“With partners like Schubert, manufacturers can set these levers in motion – and ultimately meet high consumer expectations.”
