Researchers at Fraunhofer IVV have developed a groundbreaking method to seal paper packaging without adhesives, using a CO laser to create heat-activated cleavage products. This innovation replaces synthetic sealants by transforming paper surfaces into self-adhesive materials through precise laser irradiation. The process bonds paper layers under heat and pressure, eliminating the need for traditional adhesives while maintaining structural integrity.

The team at Fraunhofer IWS in Dresden demonstrated that these fusible cleavage products function as natural adhesives, with lab tests showing seams capable of withstanding 20 kilograms of force in shear tests. By optimizing laser parameters and sealing tool geometry, researchers improved bond strength to exceed interply adhesion of paper layers. The project, led by Fraunhofer IVV scientist Fabian Kayatz, focuses on replicating industrial-scale production through a modular demonstrator at Fraunhofer IWU.

The pilot system integrates laser irradiation and heat-sealing modules into a continuous roll-to-roll process. Sensors and a digital twin monitor seam quality in real time, adjusting parameters like sealing time and temperature for optimal results. This approach allows existing packaging machinery to adopt the technology without costly overhauls. The system aims to produce 10 packages per minute by September 2026, with quality control systems tracking seam performance during operation.

Fraunhofer researchers will showcase the technology at the Interpack 2026 trade show in Düsseldorf, highlighting its potential to position companies as sustainability leaders. The modular design enables separate integration of laser and sealing components into existing production lines, offering a path for packaging manufacturers to reduce reliance on plastics and synthetic materials. This development addresses growing demand for eco-friendly packaging solutions while maintaining industrial efficiency.