14 Aug 2025

Mondi ramps up FunctionalBarrier Paper Ultimate to meet growing demand for sustainable high-barrier paper-based packaging

Investment in state-of-the-art technology enables ramp-up of ultra-high barrier paper production.
FunctionalBarrier Paper Ultimate provides outstanding protection against oxygen, water vapour and grease.
A sustainable alternative to unrecyclable multi-material packaging, the solution supports food brands in meeting circular economy goals and regulatory demands.

14 August 2025 – Mondi, a global leader in sustainable packaging and paper, is expanding its range of high-performance barrier papers with the rollout of FunctionalBarrier Paper Ultimate, a paper-based solution that meets even the most demanding packaging requirements.

Following its previously announced €16 million investment in state-of-the-art technology at its plant in Solec (Poland) Mondi is ramping up production of this high-performance barrier paper which offers exceptional protection against oxygen, water vapour and grease, with an oxygen transmission rate (OTR) below 0.5 cm³/m²d and water vapor transmission rate (WVTR) below 0.5 g/m²d. According to Mondi’s internal product impact assessments, the solution delivers substantially lower cradle-to-grave CO₂ emissions compared to conventional multi-layer plastic or aluminium-based materials^[1].

As part of the re/cycle portfolio, FunctionalBarrier Paper Ultimate meets Mondi’s internal Path to Circularity Scorecard criteria and is designed for recycling according to the Cepi Recyclability Laboratory Test Method (Version 1 – January 2025) and 4evergreen’s Recycling Evaluation Protocol for recycling mills using conventional processes. As a result, customers benefit from a more sustainable alternative to traditional, non-renewable packaging solutions.

Intended for high barrier applications, the solution is suitable for packaging instant coffee sticks and pod overwraps, tea sachets, dried food seasonings, muesli or cereal bars and bouillon cubes, among others, and ensures long shelf life and convenience.

The product complements Mondi’s broad range of FunctionalBarrier Papers, which offers customers a variety of barrier levels to suit their individual product requirements. It can help support brands’ circular economy goals by enabling customers to meet changing regulatory requirements and growing consumer demand for more sustainable packaging.

Compatible with existing horizontal and vertical form-fill-seal packing lines, the paper-based packaging can be efficiently integrated into existing production processes.

“FunctionalBarrier Paper Ultimate is the result of customer-driven innovation,” says Dirk Gabriel, COO Consumer Flexibles at Mondi. “With this solution, we are helping brands to move away from multi-material packaging that is unrecyclable, without compromising on performance. This is another concrete step towards our MAP2030 sustainability commitments of designing circular driven solutions, created by empowered people, and taking action on climate. As of today, 87% of Mondi’s packaging solutions are already reusable, recyclable or compostable.”

^[1] The product impact assessment compares conventional high-barrier structures (PAP 60/Alu 6.35/PE 30 and PET 12 / Alu 7 / LDPE 80) with Mondi paper-based FunctionalBarrier Paper Ultimate (90 gsm and 60 gsm) (end-of-life EU27).

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Notes for editors

About Mondi

Mondi is a global leader in packaging and paper, contributing to a better world by producing products that are sustainable by design. We employ 24,000 people in more than 30 countries and operate an integrated business with expertise spanning the entire value chain, enabling us to offer our customers a broad range of innovative solutions for consumer and industrial end-use applications. Sustainability is at the centre of our strategy, with our ambitious commitments to 2030 focused on circular driven solutions, created by empowered people, taking action on climate.

In 2024, Mondi had revenues of €7.4 billion and underlying EBITDA of €1.0 billion. Mondi is listed on the London Stock Exchange in the ESCC category (MNDI), where the Group is a FTSE100 constituent. It also has a secondary listing on the JSE Limited (MNP).

www.mondigroup.com