Packaging converter Masterpress has installed a Karlville Swiss pouch-forming machine at its manufacturing facility in Białystok, Poland.
The installation allows the European packaging converter to produce paper-based and single-layer polyethylene (PE) pouches in-house.
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The line connects directly to the site’s existing flexographic and digital printing presses.
Surface-printed paper and plastic substrates can move straight into pouch assembly without requiring intermediate lamination or curing stages, the company said.
Equipment delivery took place in August 2026. The line became fully operational in September following staff training and production trials across different pouch dimensions and formats.
Masterpress stated that the investment responds to customer demand for circular packaging and prepares the business for upcoming requirements under the EU Packaging and Packaging Waste Regulation (PPWR).
The system can convert substrates containing over 90% paper and more than 95% bio-based content. The resulting packaging is certified for food contact, including dry goods, spices, dietary supplements and pet food.
The material formulation contains no per- and polyfluoroalkyl substances (PFAS) or polyvinylidene chloride (PVDC).
According to the company, the substrate provides an “ultra-high barrier” against atmospheric degradation.
Under standard testing, oxygen transmission rates remained below one cubic centimetre per square metre per day, while water vapour transmission stayed below one gram per square metre per day.
Recyclability assessments carried out under Confederation of European Paper Industries (CEPI) standards confirmed the material can be processed through conventional paper mills.
Beyond paper-based and mono-PE substrates, the machine processes conventional laminates and single-layer polypropylene (PP).
It manufactures two-side-seal, three-side-seal and stand-up pouches with optional reclosable features, including easy-open zippers aligned with PPWR rules.
Eight independent servo motors control web tension across the feeding, sealing, cooling and cutting stations, allowing operators to adjust settings for delicate or single-layer substrates.
The line is configured for short, medium and long production volumes, enabling customers to run commercial trials without ordering large quantities or purchasing their own converting equipment.
Masterpress business development leader – pouches Jakub Pędziński said: “We see pouches as the future of sustainable packaging for many FMCG products because of their low material weight and lower carbon footprint compared with glass, rigid plastic and metal formats.
“This investment directly responds to the growing demand from brand owners, retailers, and consumers for high-performance packaging that balances product protection, shelf life and end-of-life recyclability.”
