Sappi launches portfolio of heat-sealable papers to accelerate plastic-to-paper transitions

As food and drink manufacturers face mounting pressure from the EU Packaging and Packaging Waste Regulation (PPWR), Sappi has unveiled the market’s most extensive portfolio of heat-sealable functional papers.

The expanded “Seal” family is designed to provide converters and brand owners with a direct, fibre-based alternative to plastic and composite structures without compromising on production speed or shelf appeal.

The portfolio — comprising Seal Silk, Seal G Silk, Seal Pure Silk, Seal Natural, Seal Light, and Seal Lucent — spans a wide range of weights from 44 to 110 gsm. By offering multiple finishes, including OBA-free and translucent options, Sappi is addressing the industry’s need for “mono-material” solutions that are fully recyclable in existing paper waste streams.

For manufacturers, the primary hurdle in moving away from plastic has often been the “risk vs. cost” factor during machine transition. Sappi has engineered the Seal range to ensure stable sealing results and strong mechanical strength, allowing the papers to run smoothly on existing packaging lines. The materials are designed to replace PE-coated papers and various plastic laminates while maintaining the “hot-tack” performance required for vertical and horizontal form-fill-seal (VFFS/HFFS) equipment.

“We’re seeing brand owners and printers look for reliable ways to change their packaging without adding risk or cost,” says Michael Bethge, sales director flexible packaging at Sappi. “They need practical choices rather than one fixed solution, along with technical support during the transition. The Seal range reflects that feedback.”

The portfolio is segmented to meet specific aesthetic and functional requirements across the grocery aisle:

• Confectionery & snacks: the Seal Silk and G Silk grades (up to 110 gsm) are optimised for multi-packs, twisted products, and Neapolitans, supporting high-quality flexo and gravure printing.
• Lightweight efficiency: the Seal Light range offers a 44 gsm option, providing a lightweight solution for converters looking to reduce material usage in sachets, stick packs, and pillow bags.
• Visibility & natural aesthetics: for brands requiring product visibility, the translucent Seal Lucent grade allows for window-style packaging. Meanwhile, the OBA-free Seal Pure Silk provides a more natural, matte look for premium or organic brands.

Recognising that switching from plastic to paper involves more than just a change in material, Sappi provides end-to-end technical support. This includes on-site guidance during trial runs to calibrate sealing temperatures, dwell times, and machine settings. This “one-stop” approach is aimed at helping manufacturers achieve a lower total cost of ownership by minimizing trial-and-error during the switch.