From Flowpacks to Reusables: Sustainable Packaging Gains Traction in the Baking Industry
Sustainable packaging has become a strategic imperative for the baking industry. Rising consumer expectations, combined with tightening regulations and ecological pressures, are prompting bakery manufacturers to seek out smarter, greener ways to package their products. Recent innovations by companies like Schubert, Syntegon, and WECARRY highlight the range of approaches being taken to address these challenges.
At the core of Schubert‘s approach is the rethinking of traditional carton-based packaging. “Because it is made from renewable raw materials, cardboard packaging comes across as sustainable at first glance. However, it is as a rule not entirely recyclable due to the glue used to seal the cardboard packaging.” This glue not only hinders recyclability but is also energy-intensive to manufacture. Schubert’s answer is its Dotlock technology: “With its new Dotlock technology, several layers of cardboard can be joined completely glue-free by reshaping them, similar to clinching metal. To achieve this, the layers are pierced from one side with a needle, creating a collar on the other side. This is then pressed onto the cardboard, creating a stable force and form fit.” This innovation allows manufacturers to create fully recyclable mono-material packaging without compromising strength or efficiency.
Meanwhile, for bakery products typically flow-wrapped—such as bars, croissants or biscuits—Schubert’s Flowpacker series offers a compatible platform for recyclable films. “It features Box Motion sealing technology, which is suitable for recyclable flowpacks made from monofilms and even paper-based films. Thanks to their gentle ultrasonic sealing process, the machines are an excellent choice for polymers with a low melting point and do not require heat protection.” Flexibility is central to this solution, allowing manufacturers to switch between materials and formats: “Flow-wrapping machines from Schubert enable switching between different sealing technologies, product formats and packaging materials.”
Syntegon, too, is addressing the need for flexibility, automation and gentle handling—particularly for sensitive bakery items such as cookies. The company is introducing its FGCT count feeder at iba 2025. “The innovative handling solution, being presented to the European market for the first time at iba, gently groups sandwich cookies in the desired quantity and places the products on-edge in trays or directly into the infeed of a flow wrapping machine.” This ensures high-speed efficiency while preserving product integrity. “Gentle handling, carefully balanced at high speed, guarantees an efficient packaging process and avoids product damage. Evenly aligned in the tray or flow wrap, the cookies impress with their quality and with optimal presentation when the package is opened.”
Automation is also a key component in addressing labor shortages and cost pressures in the baking industry. “The industry is facing complex challenges today: A shortage of skilled workers and increasing cost pressure require highly automated solutions that are not only efficient but also very flexible. At the same time, the variety of products is growing – from classic biscuits to health-conscious variants such as gluten-free or sugar-reduced cookies. These products require particularly gentle processing,” explains Daniel Bossel, product manager at Syntegon. The new count feeder is designed to adapt to these evolving demands. “From individual packaging machines to fully integrated, fully automated systems, the portfolio covers all industry requirements. Whether sensitive premium cookies or robust crackers – the systems process both at high speed.”