The developments from Fraunhofer IVV enable the use of innovative, sustainable materials, the handling of modified processing properties, and the adaptation of existing machinery and production lines. To secure long-term technological expertise, the institute will introduce a digital knowledge management system to ensure smooth operations under labor shortage conditions. The system will be accompanied by digital solutions for process efficiency and strategies to facilitate data management across the material life cycle.

“With our interdisciplinary expertise – spanning mechanical engineering, materials science, digitalization, automation, and engineering psychology – we support the packaging industry in its transition toward closed-loop value chains,” says Prof. Dr.-Ing. habil. Marek Hauptmann, Head of the Department for Packaging and Processing Technologies at Fraunhofer IVV. At interpack, he and his team will present innovations for every stage of the process chain – from safe and sustainable materials to application solutions and strategies for data-driven material life-cycle management. 

Technologies for Recyclate Material Streams

To ensure reliable and efficient sealing of mono-material films, the Fraunhofer IVV has developed the patented, innovative “HIS” technology. Compared with conventional heat-contact sealing methods, this approach reduces energy consumption by up to 95% while offering exceptional process flexibility. It is particularly suitable for demanding applications such as high-speed production processes, temperature-sensitive products, or operations with highly constrained processing windows.

Achieving the required recycled content quotas demands a robust assessment of material processability, particularly given fluctuating recycled content levels and varying material qualities. The flexible development and pilot facility “MoTiV,” operated by the Fraunhofer IVV, enables comprehensive analysis of material properties, targeted testing of process parameters and tooling, and the realization of prototypes from batch size 1. Through data-driven transfer into specific machine settings, the resulting insights can be directly implemented in industrial production environments.

The deep-drawable barrier coatings developed by the Fraunhofer IVV combine product protection and thermoformability within a recyclable mono-material concept – without compromising process stability or quality. The technology enables the safe and food-compliant use of recycled polypropylene (PP) and polyethylene terephthalate (PET) in thermoformed packaging applications.

Circular Packaging Solutions: Fiber-Based, Functional, and PPWR-Compliant

With the novel joining technology “Papure,” fully recyclable and compostable paper packaging can be produced while ensuring 100% seal integrity. “Papure” enables, for the first time, the joining of paper without the use of foreign materials such as polymer layers or adhesives. In this process, the paper is laser-pretreated and subsequently joined using a specialized heat-contact sealing method. 

In addition, the Fraunhofer IVV showcases its expertise in the development of new circular packaging solutions through a portfolio of innovative, fiber-based demonstrators. These include thermoformed paper packaging with functional barrier coatings, autonomously separating multi-material packaging systems, alternative packaging concepts based on regionally sourced peatland plants, and pouch packaging featuring functional barrier properties. To enable the application of ultra-thin inorganic barrier layers onto paper and bio-based films, the Fraunhofer IVV has developed a dedicated transfer film.

Using an indirect metallization process, stable and reproducible barrier properties can be achieved even on uneven surfaces. The barrier layer is transferred from a reusable carrier film onto the fiber-based substrate in a dedicated transfer step. This approach ensures reliable protection, even for demanding products. Recyclability and bio-based content are fully preserved, as only minimal polymer fractions are required. The process is compatible with existing production lines and does not necessitate significant capital investment.
 

Digital Solutions for Industry: Securing Knowledge, Structuring Expertise, and Enabling Intuitive Access

Under the guiding principle “Ask your company’s chatbot,” the Fraunhofer IVV has developed a digital knowledge management system designed to safeguard critical corporate expertise against loss due to staff turnover or retirement. Domain-specific knowledge content and interrelationships are systematically captured and structured using engineering psychology methodologies. A company-specific wiki with an integrated chatbot provides employees with rapid, context-sensitive access to validated knowledge whenever required.

For automated optical quality inspection and seamless production documentation, the Fraunhofer IVV introduces the operator assistance system “imageSAM”. The system automatically detects deviations and defects in the production process, identifies root causes, and links them to digitized application knowledge. In the event of disruptions, operators receive real-time, task-specific guidance for troubleshooting, enabling even less experienced personnel to adjust machine settings safely and reliably.

A further digital solution for workforce qualification comprises the VR-based training systems developed by the Fraunhofer IVV. Within immersive virtual environments, machine functions, process interdependencies, and troubleshooting procedures can be practiced independently of live production schedules. Tailored didactic concepts help reduce operating errors and shorten changeover times. An additional editor function enables users to create, update, and expand VR training modules without requiring advanced IT expertise.

Data-driven Measurement of Efficiency and Resource Consumption as well as Prediction of Product Shelf Life

For the data-driven acquisition of energy and resource consumption in relation to plant efficiency in manufacturing and packaging processes, Fraunhofer IVV introduces the data collection system “VERA.” The system combines consumption measurements with the operating states of processing and packaging machinery, enabling resource consumption to be quantified per package, per machine, or per individual process step with temporal resolution down to one second. In doing so, it provides robust empirical data for sustainability reporting requirements, such as those mandated by the Corporate Sustainability Reporting Directive (CSRD), while simultaneously identifying optimization potential.

Digital tools for the shelf life forecast developed by Fraunhofer IVV also provide reliable decision-making support for complex packaging development. Even minor modifications in material composition, film thickness, or design can significantly affect shelf life and product quality. Using advanced simulation methods, multiple scenarios can be evaluated prior to industrial-scale material production, enabling informed decisions on packaging design that achieve an optimal balance between product protection and reduction of plastic usage.

Expert contact:

Prof. Dr.-Ing. habil. Marek Hauptmann
Head of Department for Packaging and Processing Technologies
Heidelberger Str. 20 I 01189 Dresden I Germany
Phone +49 351 43614-52
marek.hauptmann@ivv-dd.fraunhofer.de