Tara Olivo, Associate Editor12.11.24
Nonwovens are increasingly being used in food packaging due to their versatility, sustainability and their ability to provide barrier properties that help preserve food freshness. Used for beverage filtration, absorbent food pads and molded applications, these materials offer a lightweight, cost-effective alternative to traditional packaging, while also enabling advancements in eco-friendly and biodegradable solutions. As the demand for sustainable packaging grows, nonwovens provide a solution to minimize environmental impact while maintaining performance.
“The market for sustainable packaging is poised for significant growth,” says Sanna Fager, chief commercial officer at PulPac, developer of Dry Molded Fiber technology. “Key drivers include heightened consumer awareness of environmental challenges, stricter regulations targeting plastic waste reduction and corporate commitments to achieving sustainability goals.”
Depending on the specific requirements, Dry Molded Fiber can offer a better fit than plastics or wet molded fiber in a wide range of applications. According to Fager, the technology enables high design flexibility with hinges, whole punching, colors, patterns, embossing, debossing, etc., in a single production step, opening new possibilities for packaging applications. “Its sustainability features, coupled with rapid production speeds, scalability and high output, make it particularly suited to high-demand sectors such as food and beverage,” Fager says.
Airlaid technology lies at the heart of Dry Molded Fiber’s innovation. “Inspired by the soft, fluffy core used in diapers, PulPac adapted airlaid techniques and combined them with a pressing system to form products into precise shapes,” Fager explains. “The flexibility and formability of the airlaid web enable the creation of complex 3D shapes without cracking, allowing for designs with greater undercuts and deeper products compared to pressed paper. Additionally, the airlaid technique efficiently customizes the final product’s strength to meet specific needs. It also eliminates water usage, supports high-speed production and reduces CO2 emissions by up to 80% compared to plastics. The result is a cost-efficient, lightweight, rigid, and responsibly manufactured packaging solution, ideal for diverse food packaging applications.”
Within the food and beverage industry, products already in the market developed with PulPac’s technology include coffee cup lids, meal trays, bowls and cutlery.
As advancements in materials, barriers and design capabilities progress, Fager says the range of applications will continue to expand. A recent example is PulPac’s collaboration with PA Consulting and Diageo on Baileys mini bottles and the iconic Johnnie Walker bottle. “These projects highlight the potential of Dry Molded Fiber to address the need for premium, sustainable packaging solutions in the beverage industry,” she says. “The future holds enormous potential for creating even more complex and diverse food-grade applications.”
According to the company, Dry Molded Fiber directly addresses the challenges of single-use plastics by providing a scalable, resource-efficient alternative. Its nearly waterless process significantly reduces energy and resource consumption. Furthermore, Dry Molded Fiber enables plastic-free products that are both recyclable and biodegradable, aligning with regulatory requirements and consumer demands for sustainable packaging. “These attributes position the technology as a key driver in the transition to greener packaging solutions,” Fager says.
PulPac collaborates with machinery suppliers like Curt G. Joa and Andritz, both renowned for their expertise in nonwoven and airlaid machine building, according to Fager. These partnerships aim to standardize and scale Dry Molded Fiber production, ensuring efficiency, reliability and cost-effectiveness.
“By leveraging their partners’ expertise, PulPac strengthens the production process, making the technology more accessible to a wider range of packaging manufacturers,” she explains. “These collaborations also foster innovation, enabling PulPac and its customers to stay competitive while adapting to evolving market needs and expanding its global reach.”
According to Luca Lavazza, Magic’s R&D manager, this product enhances fresh food shelf life by effectively absorbing and retaining liquids within trays, thus reducing spoilage and maintaining product presentation. This solution also caters to the needs of distributors seeking eco-friendly and compostable materials for fresh food packaging, aligning with the commitment to environmental responsibility.
Magic’s nonwoven airlaid materials are primarily based on cellulose and incorporate Spongel, a super absorbent biodegradable and compostable powder offering excellent absorbency and moisture retention. The high liquid absorption capacity and quick-drying features ensure that pads keep packaged food dry, extending shelf-life. Nonwoven materials, such as Airgel g-grade, are compostable and sustainable making them both effective and eco-friendly.
Magic’s nonwoven pads are designed to wick away liquids, preventing bacterial growth and reducing spoilage in fresh food packaging. “The multi-layered construction of pads ensures that fluids are retained within the core, creating a barrier that reduces the need for additives and preservatives,” says Lavazza. “This material also enhances the aesthetic presentation of food products by preventing pooling or staining, thereby making them more appealing on display.”
Magic integrates environmental sustainability into every stage of its production. Airgel g-grade and Spongel are certified OK Compost Industrial by TÜV Austria and conform to European standards for compostability. “Through R&D and process optimization, we aim to deliver packaging that supports a circular economy by being recyclable or compostable,” Lavazza explains.
“Consumers and retailers are increasingly demanding packaging solutions that are both sustainable and capable of prolonging freshness,” he continues. “There is a strong preference for compostable or recyclable pads as well as for materials that reduce food waste by extending the shelf life of fresh produce. Additionally, transparent labeling of compostable and eco-friendly materials is becoming more influential in consumer choices, prompting producers to adopt eco-certifications.”
The new Echo fruit pad extends the shelf life of berries by up to 12 hours and can be recycled or composted by the consumer.
The new Echo pads are 100% plastic-free and utilize Tensei second harvest technology, which uses alternative natural fibers to engineer the next generation of materials. The pads are made from sustainable straw crop residues, including seeds, skins and fiber crops after processing, along with perennial grasses and annual fiber crops.
In the U.K. alone, over 5.3 billion fruit pads end up in landfills each year, which is enough waste to cover almost half a million tennis courts.
“The new pads are a great opportunity for berry growers to extend shelf-life and cut food and packaging waste,” says Matt Hankins, managing director of Elliott Absorbent Products. “By switching to Echo and utilizing crop waste, we can replace 1280 metric tons of plastic or tree-sourced fiber every year.”
The pads are designed with an embossed surface that cushions the fruit and minimizes spoilage and reduces product loss and waste as confirmed by three independent tests with fruit desks and growers. With 100% surface absorbency for fungal water droplets, the pads hold approximately 500ml distilled water per square meter with no need for perforations.
The Echo product is available in pads and rolls in black-blue, allowing for ease of IR recycling recognition. The pads and rolls are cushioned and are made from pure cellulose, ensuring they are 100% plastic-free. They are certified to EU standard UNI 11743:2019, supported by CPI and accepted in U.K. recycling systems.
In addition to making use of a valuable waste product, the development of the Echo pads has created a potential new source of income for farmers. This approach addresses both packaging waste and food waste.
Figures from a 2018 DEFRA report illustrate the size of the opportunity, with 24% of baled straw, 2.87 million tons, being unused crop waste. U.K. households discard approximately 6.4 million tons of edible food each year—while globally, food waste accounts for at least 8% of greenhouse gas emissions.
“Second Harvest technology enables us to replace traditional plastic pads used for fruit packaging with fibers from agricultural waste,” says Anabelle Filer, CEO of Tensei. “This innovation promotes economic freedom, creates a significant reduction in environmental impact and end-of-life issues, allowing farmers to earn more, providing brands with valuable new options, and giving future generations hope for a more sustainable future.”
For beverage filtration, Magnera, a new leader in nonwovens formed through the merger of Berry Global’s Health, Hygiene, and Specialties Global Nonwovens and Films business with Glatfelter Corporation, employs the wetlaid (inclined wire) method. In this process, fibers such as abaca, specialized long and short fiber pulps, and artificial fibers (used for heat-sealable products) are suspended in water. These fibers are then formed and bonded together to create durable and effective filter paper. Magnera also produces a wide variety of FDA-approved nonwoven and film products used in meat, fruit, and other food pads.
Over the past decade, the company has developed biodegradable and compostable solutions for a wide range of single-serve applications, including tea bags, coffee pads, pods, and capsule systems. More than 15 years ago, the company introduced the first bio-based heat-sealable products, setting a benchmark in sustainability, the company says. Additionally, most of its non-heat sealable portfolio has met home-compostability standards.
The shift toward sustainability and compliance with regulations are key growth drivers for nonwovens in food packaging, according to the company. “Consumers and regulators increasingly demand compostable and recyclable packaging that reduces waste,” says Lukas Schmidt, Magnera sales director. “Magnera is well-positioned to capitalize on these opportunities with its expertise in sustainable materials and innovative technologies tailored to market needs.”
As part of its continued commitment to innovation and sustainability, Magnera expanded its portfolio to address the growing demand for eco-friendly packaging solutions in the single-serve coffee market.
Launched in October, Magnera’s new biobased espresso lid material replaces traditional polyethylene-coated aluminum films. Designed to be home-compostable, the lid provides critical functionalities such as oxygen and moisture barriers, clean puncture performance under high pressure, peel-free adhesion, and crema support. Unlike alternatives like PLA or PHA, which lack the same level of performance, Magnera’s lid meets both environmental and functional demands for single-serve coffee machines.
Ahlstrom is also advancing its own eco-friendly solution for the single-serve coffee market. Earlier this year, the nonwovens specialist launched PureLid, which offers a high-performing, home-compostable alternative to aluminum or plastic lids used in coffee capsules.
The company’s patented coffee lid is compatible with the most common bio-based coffee capsules on the market, making it a versatile choice for coffee brands looking to reduce their environmental footprint. PureLid also features an adequate oxygen barrier that preserves the coffee’s flavor and freshness.
PureLid incorporates a built-in filter that effectively retains dust, ensuring optimal brewing performance and a consistently pure coffee taste with every cup. One of the key features of PureLid is its transition from industrial compostability to home compostability, while maintaining capsule performance and the essential oxygen barrier.
“It was a substantial challenge to transition from industrial compostable solutions to home compostable ones while maintaining the high-performance standards of our coffee capsule lidding solutions and the crucial oxygen barrier. However, our team’s dedication and expertise have made PureLid a reality, setting a new standard for sustainable coffee packaging,” says Philippe Sevoz, vice president of the Beverage & Casing business.
PureLid has received the OK compost Home and OK compost Industrial certifications from TÜV. OK compost Home and OK compost Industrial certifications confirm that PureLid can be composted both at home and in an industrial facility. All tests have been carried out with an independent laboratory certified and accredited to ISO 17025.
Nonwoven Network, LLC is also committed to providing sustainable products. The company has developed the One Earth patented product line, which consists of environmentally friendly materials designed for tea and coffee filters. Manufactured in the U.S. from non-GMO sugar cane, One Earth’s entire product line is compostable in 14 to 21 days or less, USDA 100% Biobased, non-GMO and plastic-free. The manufacturing process is a dry process so there is no water waste or water contamination. Additionally, there are no additives, bleach, or carcinogens in the One Earth material.
The One Earth product line has recently expanded and now offers three different weights of filter material for tea, coffee, cold brew and iced tea, including 21gsm, 24gsm and 33gsm. The 21gsm is its fast brew material and great for tea products and the 24gsm material is its standard and most popular material. It is used for tea, coffee and other products, including for beauty, cleaning and pet products. The 33gsm One Earth material is used for dust-like products: Matcha, finely ground coffee, turmeric and spices. All One Earth filter materials are naturally white (not bleached) and will go clear when wet to show the tea leaves or product.
“Nonwoven Network, LLC continues to develop new products based off of our customer’s needs,” says Erin Tallaksen, managing director, One Earth. “There are a few new products in the works that we are excited to share in the coming 2025 year.”
“The market for sustainable packaging is poised for significant growth,” says Sanna Fager, chief commercial officer at PulPac, developer of Dry Molded Fiber technology. “Key drivers include heightened consumer awareness of environmental challenges, stricter regulations targeting plastic waste reduction and corporate commitments to achieving sustainability goals.”
PulPac Offers a Sustainable Alternative to Plastics
PulPac’s Dry Molded Fiber technology offers a new approach to sustainable packaging. Unlike wet molded fiber, which defibrates cellulose fibers (pulp) with water into a slurry, Dry Molded Fiber mills the fibers and airlays them into a dry fiber web. This process eliminates the need for water in forming, significantly reducing resource consumption and environmental impact.PulPac’s Dry Molded Fiber technology can be used to make sustainable coffee cup lids, meal trays, bowls and cutlery.
Depending on the specific requirements, Dry Molded Fiber can offer a better fit than plastics or wet molded fiber in a wide range of applications. According to Fager, the technology enables high design flexibility with hinges, whole punching, colors, patterns, embossing, debossing, etc., in a single production step, opening new possibilities for packaging applications. “Its sustainability features, coupled with rapid production speeds, scalability and high output, make it particularly suited to high-demand sectors such as food and beverage,” Fager says.
Airlaid technology lies at the heart of Dry Molded Fiber’s innovation. “Inspired by the soft, fluffy core used in diapers, PulPac adapted airlaid techniques and combined them with a pressing system to form products into precise shapes,” Fager explains. “The flexibility and formability of the airlaid web enable the creation of complex 3D shapes without cracking, allowing for designs with greater undercuts and deeper products compared to pressed paper. Additionally, the airlaid technique efficiently customizes the final product’s strength to meet specific needs. It also eliminates water usage, supports high-speed production and reduces CO2 emissions by up to 80% compared to plastics. The result is a cost-efficient, lightweight, rigid, and responsibly manufactured packaging solution, ideal for diverse food packaging applications.”
Within the food and beverage industry, products already in the market developed with PulPac’s technology include coffee cup lids, meal trays, bowls and cutlery.
As advancements in materials, barriers and design capabilities progress, Fager says the range of applications will continue to expand. A recent example is PulPac’s collaboration with PA Consulting and Diageo on Baileys mini bottles and the iconic Johnnie Walker bottle. “These projects highlight the potential of Dry Molded Fiber to address the need for premium, sustainable packaging solutions in the beverage industry,” she says. “The future holds enormous potential for creating even more complex and diverse food-grade applications.”
According to the company, Dry Molded Fiber directly addresses the challenges of single-use plastics by providing a scalable, resource-efficient alternative. Its nearly waterless process significantly reduces energy and resource consumption. Furthermore, Dry Molded Fiber enables plastic-free products that are both recyclable and biodegradable, aligning with regulatory requirements and consumer demands for sustainable packaging. “These attributes position the technology as a key driver in the transition to greener packaging solutions,” Fager says.
PulPac collaborates with machinery suppliers like Curt G. Joa and Andritz, both renowned for their expertise in nonwoven and airlaid machine building, according to Fager. These partnerships aim to standardize and scale Dry Molded Fiber production, ensuring efficiency, reliability and cost-effectiveness.
“By leveraging their partners’ expertise, PulPac strengthens the production process, making the technology more accessible to a wider range of packaging manufacturers,” she explains. “These collaborations also foster innovation, enabling PulPac and its customers to stay competitive while adapting to evolving market needs and expanding its global reach.”
Magic Makes Sustainable Food Pads
Magic SpA specializes in sustainable absorbent pads for food packaging, especially for fresh items like meat, fish and berries. Its core product is Airgel g-grade, leveraging compostable airlaid used as an absorbent core in the pad.According to Luca Lavazza, Magic’s R&D manager, this product enhances fresh food shelf life by effectively absorbing and retaining liquids within trays, thus reducing spoilage and maintaining product presentation. This solution also caters to the needs of distributors seeking eco-friendly and compostable materials for fresh food packaging, aligning with the commitment to environmental responsibility.
Magic’s nonwoven airlaid materials are primarily based on cellulose and incorporate Spongel, a super absorbent biodegradable and compostable powder offering excellent absorbency and moisture retention. The high liquid absorption capacity and quick-drying features ensure that pads keep packaged food dry, extending shelf-life. Nonwoven materials, such as Airgel g-grade, are compostable and sustainable making them both effective and eco-friendly.
Magic specializes in sustainable absorbent pads for food packaging.
Magic’s nonwoven pads are designed to wick away liquids, preventing bacterial growth and reducing spoilage in fresh food packaging. “The multi-layered construction of pads ensures that fluids are retained within the core, creating a barrier that reduces the need for additives and preservatives,” says Lavazza. “This material also enhances the aesthetic presentation of food products by preventing pooling or staining, thereby making them more appealing on display.”
Magic integrates environmental sustainability into every stage of its production. Airgel g-grade and Spongel are certified OK Compost Industrial by TÜV Austria and conform to European standards for compostability. “Through R&D and process optimization, we aim to deliver packaging that supports a circular economy by being recyclable or compostable,” Lavazza explains.
“Consumers and retailers are increasingly demanding packaging solutions that are both sustainable and capable of prolonging freshness,” he continues. “There is a strong preference for compostable or recyclable pads as well as for materials that reduce food waste by extending the shelf life of fresh produce. Additionally, transparent labeling of compostable and eco-friendly materials is becoming more influential in consumer choices, prompting producers to adopt eco-certifications.”
New Fruit Pads Use Agricultural Waste Fibers
U.K.-based Elliott Absorbent Products, which has been converting food absorbents since the 1980s, recently launched a recyclable and compostable pad designed to help berry producers and their customers reduce food waste and cut carbon emissions.The new Echo fruit pad extends the shelf life of berries by up to 12 hours and can be recycled or composted by the consumer.
The new Echo pads are 100% plastic-free and utilize Tensei second harvest technology, which uses alternative natural fibers to engineer the next generation of materials. The pads are made from sustainable straw crop residues, including seeds, skins and fiber crops after processing, along with perennial grasses and annual fiber crops.
In the U.K. alone, over 5.3 billion fruit pads end up in landfills each year, which is enough waste to cover almost half a million tennis courts.
“The new pads are a great opportunity for berry growers to extend shelf-life and cut food and packaging waste,” says Matt Hankins, managing director of Elliott Absorbent Products. “By switching to Echo and utilizing crop waste, we can replace 1280 metric tons of plastic or tree-sourced fiber every year.”
The pads are designed with an embossed surface that cushions the fruit and minimizes spoilage and reduces product loss and waste as confirmed by three independent tests with fruit desks and growers. With 100% surface absorbency for fungal water droplets, the pads hold approximately 500ml distilled water per square meter with no need for perforations.
The Echo product is available in pads and rolls in black-blue, allowing for ease of IR recycling recognition. The pads and rolls are cushioned and are made from pure cellulose, ensuring they are 100% plastic-free. They are certified to EU standard UNI 11743:2019, supported by CPI and accepted in U.K. recycling systems.
In addition to making use of a valuable waste product, the development of the Echo pads has created a potential new source of income for farmers. This approach addresses both packaging waste and food waste.
Figures from a 2018 DEFRA report illustrate the size of the opportunity, with 24% of baled straw, 2.87 million tons, being unused crop waste. U.K. households discard approximately 6.4 million tons of edible food each year—while globally, food waste accounts for at least 8% of greenhouse gas emissions.
“Second Harvest technology enables us to replace traditional plastic pads used for fruit packaging with fibers from agricultural waste,” says Anabelle Filer, CEO of Tensei. “This innovation promotes economic freedom, creates a significant reduction in environmental impact and end-of-life issues, allowing farmers to earn more, providing brands with valuable new options, and giving future generations hope for a more sustainable future.”
Drink it Up
In the beverage filtration category, the primary nonwovens technology used for products like tea bags and coffee filters is wetlaid nonwovens. This technology is ideal because it allows liquids to pass through while remaining water-resistant. The production process for wetlaid nonwovens is similar to that of paper making, and many of these materials are made from a blend of wood pulp or other natural fibers combined with synthetic fibers. Additionally, wetlaid nonwovens are easy to bond, making it convenient to create bags, sachets and filters.For beverage filtration, Magnera, a new leader in nonwovens formed through the merger of Berry Global’s Health, Hygiene, and Specialties Global Nonwovens and Films business with Glatfelter Corporation, employs the wetlaid (inclined wire) method. In this process, fibers such as abaca, specialized long and short fiber pulps, and artificial fibers (used for heat-sealable products) are suspended in water. These fibers are then formed and bonded together to create durable and effective filter paper. Magnera also produces a wide variety of FDA-approved nonwoven and film products used in meat, fruit, and other food pads.
Over the past decade, the company has developed biodegradable and compostable solutions for a wide range of single-serve applications, including tea bags, coffee pads, pods, and capsule systems. More than 15 years ago, the company introduced the first bio-based heat-sealable products, setting a benchmark in sustainability, the company says. Additionally, most of its non-heat sealable portfolio has met home-compostability standards.
The shift toward sustainability and compliance with regulations are key growth drivers for nonwovens in food packaging, according to the company. “Consumers and regulators increasingly demand compostable and recyclable packaging that reduces waste,” says Lukas Schmidt, Magnera sales director. “Magnera is well-positioned to capitalize on these opportunities with its expertise in sustainable materials and innovative technologies tailored to market needs.”
As part of its continued commitment to innovation and sustainability, Magnera expanded its portfolio to address the growing demand for eco-friendly packaging solutions in the single-serve coffee market.
Launched in October, Magnera’s new biobased espresso lid material replaces traditional polyethylene-coated aluminum films. Designed to be home-compostable, the lid provides critical functionalities such as oxygen and moisture barriers, clean puncture performance under high pressure, peel-free adhesion, and crema support. Unlike alternatives like PLA or PHA, which lack the same level of performance, Magnera’s lid meets both environmental and functional demands for single-serve coffee machines.
Ahlstrom is also advancing its own eco-friendly solution for the single-serve coffee market. Earlier this year, the nonwovens specialist launched PureLid, which offers a high-performing, home-compostable alternative to aluminum or plastic lids used in coffee capsules.
The company’s patented coffee lid is compatible with the most common bio-based coffee capsules on the market, making it a versatile choice for coffee brands looking to reduce their environmental footprint. PureLid also features an adequate oxygen barrier that preserves the coffee’s flavor and freshness.
PureLid incorporates a built-in filter that effectively retains dust, ensuring optimal brewing performance and a consistently pure coffee taste with every cup. One of the key features of PureLid is its transition from industrial compostability to home compostability, while maintaining capsule performance and the essential oxygen barrier.
“It was a substantial challenge to transition from industrial compostable solutions to home compostable ones while maintaining the high-performance standards of our coffee capsule lidding solutions and the crucial oxygen barrier. However, our team’s dedication and expertise have made PureLid a reality, setting a new standard for sustainable coffee packaging,” says Philippe Sevoz, vice president of the Beverage & Casing business.
Nonwoven Network, LLC’s One Earth product line of tea and coffee filter materials is made from non-GMO sugar cane.
PureLid has received the OK compost Home and OK compost Industrial certifications from TÜV. OK compost Home and OK compost Industrial certifications confirm that PureLid can be composted both at home and in an industrial facility. All tests have been carried out with an independent laboratory certified and accredited to ISO 17025.
Nonwoven Network, LLC is also committed to providing sustainable products. The company has developed the One Earth patented product line, which consists of environmentally friendly materials designed for tea and coffee filters. Manufactured in the U.S. from non-GMO sugar cane, One Earth’s entire product line is compostable in 14 to 21 days or less, USDA 100% Biobased, non-GMO and plastic-free. The manufacturing process is a dry process so there is no water waste or water contamination. Additionally, there are no additives, bleach, or carcinogens in the One Earth material.
The One Earth product line has recently expanded and now offers three different weights of filter material for tea, coffee, cold brew and iced tea, including 21gsm, 24gsm and 33gsm. The 21gsm is its fast brew material and great for tea products and the 24gsm material is its standard and most popular material. It is used for tea, coffee and other products, including for beauty, cleaning and pet products. The 33gsm One Earth material is used for dust-like products: Matcha, finely ground coffee, turmeric and spices. All One Earth filter materials are naturally white (not bleached) and will go clear when wet to show the tea leaves or product.
“Nonwoven Network, LLC continues to develop new products based off of our customer’s needs,” says Erin Tallaksen, managing director, One Earth. “There are a few new products in the works that we are excited to share in the coming 2025 year.”
