Koehler Group’s research division, Koehler Innovation and Technology, has installed a Rovema BVC 260 vertical form-fill-seal (VFFS) machine at its site in Oberkirch, Germany, to evaluate the performance of recyclable paper packaging under real-world production conditions. The installation serves as a critical expansion of the company’s existing pilot system, which currently includes a specialized test coating machine. By integrating industrial-scale packaging equipment into its research infrastructure, Koehler aims to produce and test paper-based solutions at a pilot scale before they are adopted for large-scale manufacturing. This strategic investment is designed to assess the machinability of new barrier papers, effectively shortening development cycles and mitigating the financial and technical risks associated with commercial product launches.
The new VFFS machine allows the research team to simulate the precise mechanical stresses that materials undergo during high-speed packaging processes. Christian Kölmel, Corporate Director of Technology at Koehler Innovation and Technology, highlighted the importance of bridging the gap between material science and practical application. “With this system, we’re taking a strategically important step: Our material development and application efforts are becoming more closely interlinked, not to mention that we’re systematically expanding our packaging know-how further,” Kölmel stated. “Ultimately, our goal is to make development times shorter and reduce market launch risks.” This focus on integrated testing ensures that new recyclable paper packaging formats are fully compatible with modern equipment used by brand-name manufacturers globally.
Accelerating the Transition to Circular Design
The expansion of the Oberkirch pilot system reflects a broader commitment to sustainable packaging innovation. Since its founding in 2019, Koehler Innovation and Technology has grown to include more than 120 researchers dedicated to improving the recyclability and functional properties of paper-based materials. The team employs a multi-faceted approach that combines basic research with disruptive development to create new technology platforms for products with a strong circular design. Fritz Brümmer, Head of the Specialty Paper/Process Development Department, emphasized the operational value of these pilot tests. “We want to take our findings from pilot tests and squeeze every last bit of usefulness out of them, improve quality and safety, and make innovation faster,” Brümmer noted.
This research-driven approach allows Koehler to refine the barrier properties and mechanical strength of its papers, ensuring they provide the necessary protection for food and consumer goods while remaining easily recyclable within existing paper streams. By optimizing these materials on a pilot scale, the company can provide customers with data-backed assurance regarding the performance and safety of their products. This level of technical validation is essential for brand owners who are under increasing pressure to transition away from traditional plastic-based flexible packaging in favor of more environmentally responsible alternatives.
Collaborative Development and Lifecycle Partnership
Beyond technical validation, the investment in the Rovema BVC 260 reinforces Koehler’s role as a strategic development partner for the flexible packaging industry. Alexander Rauer, Head of Business Development for Flexible Packaging Paper at Koehler Paper, explained that the goal is to provide end-to-end support throughout the entire product lifecycle. “With this investment, we’re keeping our promise of being there for our customers as development partners along the entire product lifecycle. Our goal is to create solutions that meet the needs of brand-name manufacturers and are matched to modern packaging machines,” Rauer commented.
By aligning its material development with the requirements of modern packaging machinery, Koehler ensures a smoother transition for manufacturers moving toward sustainable substrates. The ability to test and refine solutions in-house reduces the need for disruptive trials on customers’ production lines, providing a more efficient pathway to market. As the demand for sustainable packaging continues to grow, these expanded testing capabilities position Koehler Group as a leader in the development of high-performance, recyclable paper-based solutions that meet the rigorous demands of the global supply chain.
