Four Fraunhofer institutes in Germany have created a laser-based process that seals paper packaging without glue or plastic layers. The method uses a carbon monoxide laser to turn paper fibers into a natural adhesive, making paper packaging fully recyclable.
Researchers in the PAPURE project have found a way to modify paper surfaces with a laser so they can be heat-sealed like plastic. A seal just two centimeters long and three millimeters wide can hold 20 kilograms of weight.
The project brings together four Fraunhofer institutes: IAP for polymer research, IWS for laser technology, IVV for packaging engineering, and IWU for machine tools. Volker Franke, Group Manager for Laser Micro Processing at Fraunhofer IWS, leads the laser work, while Fabian Kayatz at Fraunhofer IVV coordinates the project.
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Paper packaging currently needs glue or plastic layers to stay sealed. These additives contaminate the paper during recycling and lower the quality of recycled material. This makes it harder to recycle paper products like coffee cups and food packages.
A CO laser rapidly heats the paper surface, breaking down its natural components—lignin, cellulose, and hemicellulose—into short-chain compounds. These sugar-like substances remain on the paper and melt under heat and pressure, bonding two paper layers together without any added material.
The process works with standard thicker papers already used for disposable cups and food packaging. Manufacturers could integrate the laser module into existing production lines. The sealed packages can be recycled as pure paper without removing glue or plastic layers first.
The team is still building a pilot system at Fraunhofer IWU in Dresden that will produce ten packages per minute by September 2026. The method needs further testing with different paper types and sealing conditions before large-scale use.
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Fully recyclable paper packaging could replace plastic in many products, reducing plastic waste and CO₂ emissions. The technology lets companies produce truly green packaging without changing their entire production setup. Fraunhofer will demonstrate the system at the Interpack 2026 trade show in Düsseldorf.
