New production facility in Rethem boosts capacity and quality.
Papair GmbH is commissioning a second production facility for its paper-based bubble wrap, PapairWrap, at its Rethem site in Lower Saxony. The plant has been in regular operation since the beginning of September. With a production width that has doubled, production capacity for paper-based bubble wrap is being expanded. The aim is to meet the rising demand for sustainable packaging solutions whilst optimising cost structures.
Greater automation through new plant technology
The new plant has a production width of 800 millimetres. This is more than double that of the previous pilot plant, which has been in operation since September 2023. “Whilst building the new plant, we have also further developed the manufacturing technology. In doing so, we have laid the foundations for the most modern production facility for paper-based air cushion film in Europe,” says Steven Widdel, CTO and co-founder at Papair. This leads to an optimised cost structure and makes PapairWrap attractive to new customer groups.
Improved protective function through further development
The development team has further refined the technology based on previous production. The new technology also improves the embossing result. This means better protection for all products, including cushioning bags, pre-cut sheets and coated variants.
The heart of the EU flagship project BIOWRAP
The new plant forms the technical basis for the EU project BIOWRAP. Papair is coordinating the project together with 14 partners from 7 countries. The total budget for the project is around 19 million euros, and it will run from June 2026 to May 2031. It is the first flagship project of the Circular Bio-based Europe Joint Undertaking to be awarded to a consortium led by a German organisation. The aim of the project is the industrial scaling of PapairWrap, the first fully paper-based bubble wrap on the market.
A broader product portfolio for bespoke solutions
The increased production capacity allows for larger and more versatile formats for follow-on products such as PapairBags and PapairSheets. This gives customers greater choice for their bespoke packaging solutions. Coatings offering scratch protection, as well as water- or oil-repellent variants, remain available and tested for all products.
New customers, more sustainable supply chains
With this increased capacity, Papair will in future also be able to supply large industrial suppliers. The company is thus contributing to more sustainable supply chains in the packaging industry and meeting the growing demand for plastic-free packaging materials.
Pilot plant to form the basis for innovation processes
The previous plant went into operation in Rethem in August 2023. Until now, it has produced all customer orders. In future, it will once again serve as a pilot plant, which was its original purpose. This will enable process developments, tests and new products to be driven forward in parallel with ongoing production operations.