The idea of using paper as secondary packaging is nothing new. KHS made its first attempts around 20 years ago. "Back then, however, the technology didn't catch on because paper was a cost-intensive raw material and wrapping with film delivered better results in terms of stability," explains Karl-Heinz Klumpe, Product Manager Packaging at KHS. The beverage industry opted for other solutions.

"Our customers now want alternatives to conventional packaging solutions such as film. These should be as environmentally friendly as possible," says Klumpe. The paper wrap was therefore developed together with an international beverage manufacturer. This form of pack can replace shrink film or wrap-around cartons as transport and sales packaging for 12 or 24-pack containers - in the high-performance range, for example, with an output of up to 90,000 cans per hour.

Few process adjustments thanks to modular machine design
Only a few adjustments need to be made to the Innopack Kisters traypackers in order to wrap packs in paper instead of film. "KHS is increasingly offering modular solutions that enable and facilitate the corresponding conversions to the machines. In this case, we have only revised the process module for folding and wrapping," explains Klumpe. "The standard components, such as separating trays from the magazine, gluing or can feeding, are identical to the hundreds of KHS machines that have already proven themselves on the market." Fillers can have their existing tray packers converted by adapting individual modules; a completely new investment is not necessary.

According to Klumpe, wrapping in paper offers numerous advantages over other materials. "On the one hand, it is more environmentally friendly than film, for example in terms of marine pollution. Paper disintegrates in nature after a few weeks." On the other hand, the use of packaging material is reduced. Instead of a solid wrap-around box or film packaging with a tray, only a stable and flat corrugated cardboard sheet is required as a base when wrapping in thinner paper - with identical results in terms of stability.

In addition, the new packaging reduces costs by up to 15 percent compared to a wrap-around carton; compared to film, they are at a comparable level. The low energy consumption per hour of around 14 kilowatt hours at 80 cycles per minute also significantly reduces costs. The folding process also means that the pack is completely closed. "With film packs with small openings on the sides, dirt can get in. Paper has clear advantages when it comes to protecting the packs, especially on long transport routes," explains Klumpe.

Klumpe sees great potential for the new KHS technology. "When I think about how much food is filled into cans around the world, we offer a sensible alternative to conventional secondary packaging with paper wrapping. With our solution, we can make a significant contribution to reducing plastic waste." The efforts of the entire industry with regard to environmental protection are thus taken into account, says Klumpe. "But sustainability is also always a cost factor. We combine both with this new approach." as