Getting a good seal on sustainable packaging can be difficult, especially on high-speed bar lines. Because these films can be more porous, weakening the oxygen barrier, and costly, it’s more difficult for bakers to adopt them because they are working to lengthen shelf life while keeping costs down.

“Monofilms are becoming increasingly popular for bars,” said Luc Jamet, project manager, Schubert North America. “Due to the speed requirements, cold-seal applications are often used at the moment, but there is a growing trend toward heat-seal films driven by sustainability concerns. This allows the same film to be used, simply omitting the cold-seal coating.”

He said the challenge with monofilms is the risk of burning the film before the sealing temperature reaches the sealing surface, but that can be addressed with ultrasonic sealing and flying cross-sealing, which Schubert uses.

Yasha Shamayeli, director marketing strategy, Plan It Packaging, said manufacturers are developing mono-material films that are easier to recycle. 

He suggested that bakeries can start with hybrid approaches, such as partially recyclable or compostable materials, and test them before making a switch. Partnering with material suppliers for volume discounts can offset costs.

“New plant-based or compostable films are emerging with improved barrier properties, rivaling traditional plastics in oxygen and moisture protection,” he said.

Europe is full steam ahead on sustainability efforts, said Bill Kehrli, vice president sales and marketing, Cavanna Packaging, but he’s not seeing as much support for green packaging in the United States.

“I don’t see Americans all that excited about recyclable films,” he explained. “Even the biodegradable ones have to run so slow, it’s hard for companies to make money at that low speed.”

Liam Buckley, IMA Ilapak sales director, North America, pointed out that definitions of sustainability can vary widely.

“Most bars remain in standard laminates of BOPP [biaxially oriented polypropylene] with a sealant layer; single layer films are typically cold seal,” he explained. “Paper films are under consideration but only on premium brands at this point.”

This article is an excerpt from the March 2025 issue of Baking & Snack. To read the entire feature on Bar Packaging, click here.