Emerges as an Alternative toMultilayer Plastic Packaging
Sappi’s Guard Pro OHG offershigh barrier protection,recyclability and machinecompatibility without compromisingperformance.
With proposed regulatorychanges encouraging sustainablepackaging solutions, thePan Masala industry is activelyexploring alternativesto conventional multilayer plastic laminates.
One of themost discussed innovations ishigh-barrier functional paperpackaging. To understand itspractical viability, TobaccoPlus interacted with Filip vanRanst, Sales Director SpecialityPapers at Sappi Europe.
During the discussion, Filipshared insights about Sappi’sGuard Pro OHG paper packagingsolution, its barrierproperties, recyclability, machinecompatibility, regulatorycompliance and commercialfeasibility for the Indianmarket.
Filip revealed that the paperachieves a Water VapourTransmission Rate (WVTR) of3 g/m²/day at 38°C and 90%relative humidity, while OxygenTransmission Rate (OTR) standsat 4 cc/m²/day at 23°C and 50%relative humidity.
Paper-Based Structure with High BarrierPerformance
In response to a question regarding the materialcomposition of the packaging, Filip told TobaccoPlus that Guard Pro OHG is manufactured usingvirgin fibre-based paper combined with a water-based dispersion varnish. According to Europeanregulations, the structure is classified as a monomaterialpaper solution and can be recycled throughthe conventional paper waste stream.
Explaining the barrier performance, he said thatSappi offers a wide portfolio of functional paperswith moisture, oxygen and aroma barrier properties.For Pan Masala applications, Guard Pro OHG is themost suitable grade as it provides high protectionagainst moisture and oxygen while maintaining aromaretention and heat-sealing functionality.
Filip revealed that the paper achieves a Water VapourTransmission Rate (WVTR) of 3g/m²/day at 38°C and90% relative humidity, while OxygenTransmission Rate (OTR) stands at 4cc/m²/day at 23°C and 50% relativehumidity.
Designed for Pan MasalaApplications
When asked about productcompatibility, Filip informedTobacco Plus that Guard Pro OHGis currently being tested for PanMasala, Zarda and mouth freshenerapplications.
He stated that the paper demonstratesstrong resistance against differentproduct chemistries, includingtobacco, lime, catechu, flavouringcompounds and essential oils.
According to him, the barrierperformance helps maintain productfreshness, texture and fragrancethroughout the intended shelf life.
Shelf Life of 4–6 Months
Addressing concerns regarding product stability, Filipsaid that Guard Pro OHG can preserve freshness andaroma for at least four to six months under normalstorage conditions.
He informed Tobacco Plus that Sappi has alreadyconducted successful comparisons againstconventional multilayer packaging in severaldemanding applications requiring similar barrierperformance. However, dedicated shelf-life studiesspecifically for Pan Masala under extreme Indiansummer and humidity conditions are still underway.
Compatible with Existing Packaging Machines
One of the industry’s biggest concerns is machinecompatibility. Responding to this issue, Filip explainedthat Guard Pro OHG can run on existing VFFS, HFFSand pouch packaging machines with little or nomodification.
He noted that paper structures require wellmaintainedmachines because paper is less forgivingthan plastic films. Nevertheless, Sappi has successfullyoperated similar applications at packaging speedsexceeding 2,000 packs per minute.
Regarding sealing requirements, Filip said thatstandard sealing temperatures are generally sufficient.For contact sealing systems, temperatures between140°C and 180°C are typically recommendeddepending on production speed.
He further added that Sappi’s application engineeringteam possesses over a decade of experience in high-barrierpaper packaging and provides technicalsupport wheneverrequired.
Food Contact Compliance and MigrationSafety
In response to questions about regulatory compliance,Filip told Tobacco Plus that all Sappi barrier paperscomply with major European and US food-contactregulations.
Guard Pro OHG has been assessed according toBfR XXXVI, FDA Sections 176.170 and 176.180,EU Regulation 1935/2004 and Italian DM 21.3.73standards.
He also confirmed that migration testing has beensuccessfully completed using various food simulants,including fatty, moist and acidic conditions. Based onthese results, the paper can safely be used in directcontact with dry, moist, fatty and acidic food products.
Regarding FSSAI compliance, Filip explained thattesting through NABL-accredited laboratories in Indiawould be required. Based on Sappi’s experience, hebelieves the paper is capable of meeting the relevantrequirements.
No Commercial Disadvantage at Scale
Discussing cost considerations, Filip emphasizedthat commercial viability has been a key objectivethroughout the development process.He stated that when used at comparable industrialscale and considering environmental impact, GuardPro OHG presents no significant cost disadvantagecompared to conventional multilayer plasticpackaging.
For commercial orders, the minimum order quantitycurrently corresponds to a full container load ofapproximately 22 tonnes. However, Filip believes thatonce adoption reaches scale, opportunities will also beavailable for small and medium-sized manufacturers.
He further assured that Sappi’s global manufacturingand logistics network can support large-scale supplyrequirements in India.
Recyclability Backed by Industrial Testing
When asked about sustainability claims, Filip clarifiedthat all Sappi functional papers are recyclable inconventional paper recycling mills.He informed Tobacco Plus that Guard Pro OHGhas already been tested at industrial scale in Europeand the United States and, therefore, should also berecyclable within India’s paper recycling ecosystem.
The paper has been certified by independentlaboratories according to CEPI/4evergreenmethodologies. Filip added that recovery rates exceed80% in laboratory testing and can be even higherunder industrial recycling conditions.
Suitable for Small Sachets and ToughDistribution Conditions
Addressing practical industry concerns, Filipconfirmed that Guard Pro OHG can withstandtransportation and storage requirements encounteredin commercial distribution.
Depending on the paper grade and basis weight,puncture resistance ranges between 4 and 6 Newtons.He also confirmed that the material supports high-qualityprinting for branding, statutory warnings andpromotional communication.
Importantly for the Pan Masala industry, Filip statedthat the paper can also be used forsmall-formatsachets such as ₹2 and ₹5 packs etc.
Technical Support for Industry Transition
In response to questions regarding implementationsupport, Filip said that Sappi offers trial runs,technical assistance and customization support formanufacturers.
He further indicated that industrial-scale deploymentcan be achieved within approximately three monthsfrom a commercial agreement, enabling relativelyquick adoption by interested companies.
A Realistic Alternative to Multilayer Plastics
Summarizing the potential of the technology, Filiptold Tobacco Plus that Guard Pro OHG can realisticallyreplace conventional multilayer flexible packagingwithout compromising product safety, shelf life,operational efficiency or commercial viability.
With growing sustainability requirements andincreasing pressure on non-recyclable packagingformats, high-barrier paper solutions such as GuardPro OHG may offer the Pan Masala industry a practicalpathway toward compliance while maintainingperformance standards.