Prymat, the Polish dried seasoning manufacturer, partnered with Mondi to transition from complex multilayer packaging to a recyclable, ultra-high-barrier paper solution – achieving premium product protection while delivering a significantly lower CO₂ impact compared with conventional multi-layer plastic or aluminium-based solutions. Their challenge: spices demand extremely high barrier protection to preserve aroma, color and freshness, making the shift to recyclable paper far from straightforward.
Reaching this performance level required close collaboration and iterative testing. Through a two-year collaboration, Prymat and Mondi worked hand in hand to develop a packaging solution that meets these demanding criteria while supporting Prymat’s broader circularity ambitions.
“We work closely with brands to thoroughly learn about every step of their production, distribution and end use, so that we can create and test various options and be sure we are delivering the best possible and most sustainable outcome,” said Adrian Goralski, managing director, Mondi Solec,
The challenge: matching ultra-high barrier requirements with circular economy targets, Dried spices require exceptionally low oxygen transmission rate (OTR) and water vapour transmission rate (WVTR) values to preserve aroma, colour and freshness. Historically, that has required multi-material plastic or aluminium laminates – materials that are difficult to recycle and inconsistent with Prymat’s long-term sustainability targets.
Prymat needed a packaging solution that could combine—Ultra-high barrier performance to ensure long-lasting freshness; Recyclability that aligns with European standards; Compatibility with existing filling lines; Strong shelf appeal through high-quality print finishes; and A smooth transition without new machinery investments .
The solution: Mondi’s re/cycle FunctionalBarrier Paper Ultimate
Mondi addressed these challenges with its re/cycle FunctionalBarrier Paper Ultimate – a recyclable, next-generation paper-based solution engineered to achieve premium product protection.
This paper structure contains at least 80% high-quality paper combined with a functional barrier coating optimized for recycling. Its performance matches, and in some cases exceeds, traditional multi-material packaging.
Key features include— Ultra-high barrier properties (OTR < 0.5 cm³/m²/day, WVTR < 0.5 g/m²/day); CEPI-verified recyclability; Exceptional stiffness and dead-fold behaviour; Excellent printability to enhance Prymat’s shelf presence.
How Mondi and Prymat codeveloped a customized high-barrier paper
The development process was rooted in deep customer insight. Over two years, Mondi and Prymat jointly tested various sustainable packaging solutions, adapting barrier performance, stiffness and machinability until the optimal material was identified.
A key advantage of the final structure was its seamless integration into Prymat’s existing filling lines, meaning that no new equipment or machinery upgrades were required. This ensured a smooth transition to the new material while minimising operational complexity and maintaining production efficiency.
“Thanks to our collaboration with Mondi, we were able to develop a solution that aligns our sustainability ambitions with the highest standards of product quality,” said Marta Klęka-Nowa, PR manager, Prymat.
The outcome: enhanced product protection and shelf appeal with functional barrier paper
Partnering with Mondi enabled Prymat to elevate its product offering while supporting its sustainability goals. The new paper-based packaging protects aroma, flavour and freshness just as effectively as traditional multilayer plastic or aluminium structures. It also enhances shelf appeal thanks to high-quality print performance and supports operational efficiency, as it runs smoothly on existing filling lines without requiring machine modifications.
A scalable approach to circular packaging
Prymat’s transformation shows how ultra-high barrier paper can meet strict product requirements without compromising recyclability or production efficiency. As more food manufacturers seek credible pathways to circularity, Mondi’s FunctionalBarrier Paper Ultimate offers a future-ready solution that balances sustainability with technical excellence.
