Foldable recycle ready paper-based wrapper for butter and margarine

Abstract

A paper-based wrapper that is optimized for recycling in sorting processes utilizing an optical sorting machine. The paper-based wrapper is useful for butters and margarines and includes a first paper layer, a second paper layer, and a barrier layer positioned between the first paper layer and the second paper layer. The paper-based wrapper is provided in an assembly that includes at least 50% paper by total weight and preferably 85% paper by weight. The paper-based wrapper includes features to better enable folding during assembly of the wrapper into a package.

Description

[0001] Foldable Recycle Ready Paper-Based Wrapper for Butter and Margarine

[0002] TECHNICAL FIELD

[0003]

[0001] This disclosure is related to a paper-based wrapper designed for folding around food items that is provided in a structure ready for recycling. More particularly this disclosure is related to a foldable wrapper for butters and margarines that includes paper materials to enable recyclability in facilities using optical sorting methods.

[0004] BACKGROUND

[0005]

[0002] It has become increasingly important to design packaging structures that are more sustainable. Increased sustainability may be in the form of using raw materials that are renewably resourced, such as paper, or other fiberbased materials. Further, increased sustainability may be in the form of designing structures that have increased recyclability, compostability, or biodegradability through a choice and arrangement of materials that can be disposed of in a sustainable manner.

[0006]

[0003] For some materials that are recyclable, such as, but not limited to paper-based wrappers for butters and margarines, the disposal process requires a sorting step to segregate like materials into a dedicated recycling stream for additional and specific processing. Often, this sorting step entails the operation of an optical sorting machine having an infrared signal that is used to identify these certain material types. This optical sorting can be helpful, but, similar to most automated process, may also be prone to misidentification resulting in an improper sorted classification of certain materials. One material type that is prone to misidentification is wrapper materials, and in particular, paper-based wrappers that have a metalized layer. Therefore, there is a need within the art for the optimization of recyclable packaging so that it is compatible with current optical sorting processes.

[0007] SUMMARY

[0008]

[0004] The developments described herein provide an improved paper-based recyclable wrapper that has been optimized for recycling. The paper-based wrapper is generally a multi layered laminate comprising a fiber content of at least 50% to ensure that it is categorized for recycling within a paper / paper- cardboard recycling stream. The paper-based wrapper further comprises a barrier layer to provide a functional and / or water and / or light barrier to ensure product quality and safety. This barrier layer may be a metalized layer. The barrier layer is generally positioned at an interior of the wrapper and surrounded by a pair of distinct paper layers. The pair of paper layers includes a first paper layer generally positioned at an exterior of the wrapper and a second paper layer generally aligned as a product contact layer. This configuration ensures that the paper-based wrapper is identified as being paper from both an interior surface and an exterior surface when subjected to optical sorting.

[0009]

[0005] As the paper-based wrapper is a laminate, the paper layers and barrier layers are affixed together in a cohesive assembly. This affixing may be through the use of an adhesive layer or through an extrusion lamination of the barrier layer between the paper layers. No matter how the multiple layers of the laminate (first paper layer, second paper layer, barrier layer) are assembled (adhesive lamination, coextrusion), the assembly is further optimized to enable folding. In the case of an adhesive lamination, the adhesive layer is a partial layer of adhesive. In some embodiments, this adhesive is a line. In yet other embodiments, this adhesive is positioned as a linear sequence of dots. In still further embodiments, this adhesive is shaped in the form of a design, such as, but not limited to, a product logo or other identifying mark. In the case of an extrusion lamination, this adhesive material is specifically applied as a thin layer to enable folding.

[0010]

[0006] In some embodiments, the first paper layer is calendared paper, and the second paper layer is a grease proof paper.

[0011]

[0007] In further embodiments, the first paper layer may include a print layer.

[0012] In additional embodiments, the first paper layer may include an overlacquer, a primer, or other similar coating.

[0013]

[0008] In addition to the paper-based wrapper as a structure, the disclosure includes preferred methods of manufacture for the various embodiments. In a first method of manufacture, the paper-based wrapper is constructed from partial laminations utilizing a pair of adhesive layers. In another method of manufacture, the paper-based wrapper is constructed through an extrusion lamination.

[0014]

[0009] The paper-based wrapper is generally provided in an assembly that is designed for use in packaging food items, such as, but not limited to butters or margarines by folding the wrapper around the food item. By a specific arrangement of the layers and assembly methods, the wrapper structure is selected to be properly identified as paper in an optical sorting process during recycling.

[0015] BRIEF DESCRIPTION OF THE DRAWINGS

[0016]

[0010] The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

[0017]

[0011] FIG. 1 is a cross-sectional view of a paper-based wrapper, according to the present disclosure;

[0018]

[0012] FIG. 2 is a cross-sectional view of the paper-based wrapper with optional layers, according to the present disclosure;

[0019]

[0013] FIG. 3 is a cross-sectional view of an alternate embodiment of the paper-based wrapper, according to the present disclosure;

[0020]

[0014] FIG. 4 is a cross-sectional view of an alternate embodiment of the paper-based wrapper, according to the present disclosure; and

[0021]

[0015] FIG. 5 is a view of a package formed from the paper-based wrapper, according to the present disclosure.

[0022]

[0016] The drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale, and the same (or similar) reference numbers denote the same (or similar) features throughout the drawings.

[0023] DETAILED DESCRIPTION

[0024]

[0017] The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments, which are also referred to herein as “examples," are described in enough detail to enable those skilled in the art to practice the invention. The embodiments may be combined, other embodiments may be utilized, or structural, and logical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. Before the present invention is described in such detail, however, it is to be understood that this invention is not limited to particular variations set forth and may, of course, vary.

[0025]

[0018] Various changes may be made to the invention described and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process act(s) or step(s), to the objective(s), spirit or scope of the present invention. All such modifications are intended to be within the scope of the disclosure made herein.

[0026]

[0019] Unless otherwise indicated, the words and phrases presented in this document have their ordinary meanings to one of skill in the art. Such ordinary meanings can be obtained by reference to their use in the art and by reference to general and scientific dictionaries.

[0027]

[0020] References in the specification to “one embodiment” indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment.

[0021] Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0028]

[0022] The following explanations of certain terms are meant to be illustrative rather than exhaustive. These terms have their ordinary meanings given by usage in the art and in addition include the following explanations.

[0029]

[0023] As used herein, the term “and / or” refers to any one of the items, any combination of the items, or all of the items with which this term is associated.

[0030]

[0024] As used herein, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise.

[0031]

[0025] As used herein, the terms “include,” “for example,” “such as,” and the like are used illustratively and are not intended to limit the present invention.

[0032]

[0026] As used herein, the terms “preferred” and “preferably” refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances.

[0033]

[0027] Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.

[0034]

[0028] It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the teachings of the disclosure.

[0035]

[0029] There is a need for an improved paper-based wrapper that is optimized for optical sorting in a recycling process that utilizes this type of sorting step. The paper-based wrapper is configured to have specific usefulness for products that contain fat and / or are considered to be wet when packaged, such as, but not limited to, butters and margarines. The paper-based wrapper has at a minimum 50% paper by weight of the total wrapper to be categorized as a paper material for qualification within various recycling streams. In preferred embodiments, this paper amount is greater than 80% with the paper-based wrapper optimized for fiber recovery during the recycling process. The proportion of non-paper material is minimized and easily separable to enable efficient fiber recovery. In addition to the amount of paper, the paper-based wrapper is configured with a structure amenable and optimized for folding around a food item to form a package.

[0036]

[0030] Referring now to FIGS. 1-5, providing cross-sectional views of a paperbased wrapper and use of the paper-based wrapper for a package. The paper-based wrapper 10 is recyclable and optimized for recycling within a paper-based recycling stream utilizing common optical sorting techniques. Referring now to FIG. 1 , the paper-based wrapper 10 is a multilayer laminate comprising a first paper layer 101, a second paper layer 102, and a barrier layer 103 positioned between each of the first paper layer 101 and the second paper layer 102. The positioning of the barrier layer 103 relative to the paper layers 101 , 102 ensures proper optical identification of the wrapper within a paper-based recycling stream when the barrier layer 103 is a metalized layer or other non-paper material.

[0037]

[0031] The first paper layer 101 includes a first paper layer first side 110 and a first paper layer second side 111 with the first paper layer second side 111 opposed the first paper layer first side 110. The first paper layer first side 110 is positioned at an exterior surface of the multilayer laminate of the paperbased wrapper 10. The first paper layer 101 is preferably comprised of a repulpable calendared, optionally coated, paper having a grammage in a range of about 30 grams / meter2(gsm) to 70 gsm. In still further preferred embodiments, the first paper layer 101 is a calendared paper in a grammage of about 50 gsm.

[0038]

[0032] The second paper layer 102 includes a second paper layer first side 120 and a second paper layer second side 121 with the second paper layer second side 121 opposed the second paper layer first side 120. The second paper layer second side 121 is positioned as a product contact layer, wherein this second paper layer second side 121 is directly adjacent the product when packaged and also at a second exterior surface of the paper-based wrapper 10. Accordingly, the second paper layer second side 121 comprises a repulpable grease proof paper that is approved for food contact. The second paper layer 102 including the second paper layer second side 121 is preferably comprised of a grease proof and / or grease resistant paper having a grammage in a range of about 30 gsm to 60 gsm. In preferred embodiments, the second paper layer 102 is a grease proof paper having a grammage of about 35 gsm. As used herein, grease resistant and / or grease proof paper refers to a paper material that includes a treatment to prevent the absorption of certain materials, such as, but not limited to, fats and oils, into the paper; this treatment does not impact the ability of the paper to be recycled or repulped or to be considered a material other than paper.

[0039]

[0033] The barrier layer 103 is a functional barrier that can additionally provide a barrier to water and / or light. In some embodiments the barrier layer 103 is a metalized layer. In still further embodiments, the barrier layer 103 is a polymeric film, such as, but not limited to, a polyester (PET) film, a polypropylene (PP) film, or a polyethylene (PE) film. In yet other embodiments, the barrier layer 103 is an extrusion lamination of a polymeric material, such as, but not limited to an extrusion lamination of a polyethylene (PE), a polypropylene (PP), or other similar polymers and combinations thereof.

[0040]

[0034] Referring now to FIG. 2, an alternate embodiment of the paper-based wrapper 10 is shown. This embodiment of the paper-based wrapper 10 includes the addition of optional layers in the form of a print layer 106 and an overlacquer 107 positioned on the first paper layer first side 110. These optional layers are generally utilized to provide graphics and markings, protect these graphics and markings, and / or to provide additional surface characteristics to the first paper layer 101 exterior surface. Accordingly, the print layer 106 is an ink layer applied to the first paper layer first side 110, such as through a flexographic or rotogravure printing process. The ink on the print layer 106 may utilize solvent-based, solvent-less, or water-based ink(s) and / or ink systems.

[0041]

[0035] Referring now to FIGS. 3-4, further alternate embodiments of a paperbased wrapper are referred to herein and shown as wrapper 10’. The wrapper 10’ is a multilayer laminate constructed utilizing adhesive lamination. Accordingly, the wrapper 10’ includes the first paper layer 101 , the second paper layer 102, the barrier layer 103, a first adhesive layer 104, and a second adhesive layer 105. The first adhesive layer 104 is positioned between the barrier layer 103 and the first paper layer 101. The second adhesive layer 105 is positioned between the barrier layer 103 and the second paper layer 102.

[0042]

[0036] In a preferred embodiment of the wrapper 10’, the first adhesive layer

[0043] 104 and the second adhesive layer 105 are partial layers of adhesive. The partial nature of the first adhesive layer 104 and of the second adhesive layer

[0044] 105 enables for a more efficient recovery in a fiber repulping process. In addition to efficient fiber repulping, the partial nature of the first adhesive layer 104 and of the second adhesive layer 105 is particularly useful when folding the wrapper 10’ around a product. In preferred embodiments, the first adhesive layer 104 and the second adhesive layer 105 are provided in a dedicated pattern, such as a logo and / or a design, a distinct line in a horizontal or a vertical direction relative to the machine direction of the laminate, a series and / or a sequence of dots, and / or combinations thereof. Similar to previous embodiments related to the paper-based wrapper 10, the wrapper 10’ may also include the optional print layer 106 and the optional overlacquer 107.

[0045]

[0037] Referring now to FIG. 5, a package 108 is shown. The package 108 can be comprised of the paper-based wrapper 10 or the wrapper 10’, wherein the designated wrapper (10 or 10’) is manipulated to be folded around a food item to be packaged to generally protect and maintain freshness of the food item.

[0046]

[0038] In a preferred method of manufacture for the paper-based wrapper 10, the paper-based wrapper 10 is produced through a coextrusion process. Accordingly, the first paper layer 101 is provided along with the second paper layer 102 in the preferred composition with the first paper layer 101 being a calendared paper and the second paper layer 102 being a grease proof and / or grease resistant paper. The first paper layer 101 is then joined to the second paper layer 102 through a coextrusion of polymer between the layers to form the barrier layer 103 and resulting paper-based wrapper 10. The paper-based wrapper 10 can optionally be printed with the addition of the print layer 106 and optionally coated with the overlacquer 107, if desired. In an embodiment assembled according to this processing configuration, the barrier layer 103 is preferably provided in a grammage of about 6 to 8 gsm from an extrusion lamination of PE. This is preferred as it is considered to be a light adhesive layer and provides a good rate of repulpability of the paper-based wrapper 10 during recycling processing. The multilayer laminate forming the paper-based wrapper 10 from the above processing steps and preferred constituents results in a laminate having a total weight of about 95 gsm including more than 85% paper by total weight of the paper-based wrapper 10.

[0047]

[0039] In a preferred method of manufacture for the wrapper 10’, the wrapper 10’ is produced through an adhesive lamination process in a combination of partial laminations. Accordingly, the first partial lamination includes an optional printing step to add print layer 106 and / or optional overlacquer 107 which may be applied to the first paper layer first side 110. First partial lamination includes the application of the first adhesive layer 104 as a partial layer between the first paper layer second side 111 and the barrier layer 103. In this preferred method, the barrier layer 103 is a thin PET film or PP film with or without metallization having a thickness in a range of about 3pm to 8pm, preferably with a thickness in a range of about 4pm to 6pm. A second partial lamination is then provided to adhere the barrier layer 103 and the first paper layer 101 to the second paper layer 102, wherein the second adhesive layer 105 is provided as a partial layer between the barrier layer 103 and the second paper layer 102. Preferably, the partial lamination described above may include the application of the first adhesive layer 104 and the second adhesive layer 105 in a line, sequence of dots, and / or logo / design to allow for improved folding and recognition. In a preferred composition, the first paper layer 101 is a calendared paper and the second paper layer 102 is considered to be a grease proof and / or a grease resistant paper. The multilayer laminate forming the wrapper 10’ from the above processing steps and preferred constituents may result in a laminate having a total weight of about 95 gsm including more than 85% paper by total weight of the wrapper 10’.

[0048]

[0040] As used herein, the term paper, fiber, and / or fiber-based or paperbased may include, but not be limited to, cellulose and / or cellulose-based fibers including virgin cellulose-based fibers, recycled fibers including materials like paper fibers and craft papers, textiles, non-wovens, wood-based fibers, cotton, linen, hemp, sugar cane or sorghum commonly known as bagasse fibers, or grains. These fibers may be untreated and / or treated to provide enhancements or improvements to their inherent properties. These fibers may be provided in a plurality of dimensions / lengths including micro and nano fibrillated types, such as, but not limited to, microfibrillated and / or nanofibrillated cellulose. Further, these fibers for a fiber-based article may contain fluff pulp and / or another fiber type and may be provided in a roll, bale, blank or sheet form, continuous web, and / or may be formed from an airlaid process, and / or may be provided in a slurry. A paper, fiber, and / or fiber-based or paper-based material may comprise a coating for additional functionality. Further, the use of paper, fiber, or fiber-based materials may provide a multitude of end of use options for the paper-based wrapper 10, the wrapper 10’ and / or the package 108 wherein the wrappers and / or the package may be recycled, repulpable, or be considered to be responsibly disposable.

[0049]

[0041] The term “film” or “film portion”, such as the barrier layer 103, the paper-based wrapper 10, and the wrapper 10’ as used herein, refers to a web built of layers and / or films, all of which are directly adjacent to and connected to each other. A film can be described as having a thickness that is insignificant as compared to the length and width of the film. Films are generally regarded as having two major surfaces, opposite each other, expanding in the length and width directions. As used herein, a “laminate,” “multilayer laminate,” or “multilaminate” is a film that may be built from an unlimited number of films and / or layers, such as paper layers. The films and / or layers are bonded together by any known process such as, but not limited to, coextrusion, coating or laminating, to form a composite article.

[0050]

[0042] As used herein, the term “adjacent” means that the items, such as layers of a film, are near each other, with or without intervening material, such as adhesive. As used herein, the term “directly adjacent” or “in direct contact with” means that the items are in contact with each other, without intervening material.

[0051]

[0043] The term “package" is used herein to describe an article that may house an object (i.e. , a product, a food item), the article formed by shaping, molding, or folding a substrate and / or material into a defined shape to form the package. A “packaged product" refers to the one or more packaging components forming a sealed package and / or wrapping the product therein. Sealed packages generally have a need for storage and package integrity over a period that is greater than a few days. Package integrity includes a consistent appearance, maintenance of barrier properties, maintenance of lamination bonds, and maintenance of seals.

[0052]

[0044] The product may be any type of food, beverage, pharmaceutical or other medical aid, nutraceutical, consumer good or industrial good, or products. The product may include a wet or fatty layer. Examples of products include, but are not limited to butters, margarines, cheeses, certain dairy or non-dairy products.

[0053]

[0045] The packaged products disclosed herein may include a package formed from at least one fiber-based material in an amount to enable sustainability or categorization as a fiber-based or paper-based material. The fiber component may be in an amount of about 50% or may be in an amount greater than 80% by total weight of the package and optionally other components. Preferably, the amount of fiber within a given package or the wrappers may be greater than 85% by total weight.

[0054]

[0046] As used throughout this application, the term “polypropylene” or “PP” refers to a plastomer, homopolymer or copolymer having at least one propylene monomer linkage within the repeating backbone of the polymer. The propylene linkage may be represented by the general formula: [CH2CH(CH3)]n. Such polypropylene may be a polypropylene impact copolymer, a polypropylene random copolymer, or a polypropylene homopolymer, may be syndiotactic or isotactic, or may or may not be clarified.

[0055]

[0047] Polyethylene is the name for a polymer whose basic structure is characterized by the chain -(CH2- CH2-)n. As used herein, the term "polyethylene" or “PE” includes homopolymers and copolymers of ethylene. Polyethylene homopolymer is generally described as being a solid which has a partially amorphous phase and partially crystalline phase with a density of between 0.870 to 0.980 grams per cubic centimeter. The relative crystallinity of polyethylene is known to affect its physical properties. The amorphous phase imparts flexibility and high impact strength while the crystalline phase imparts a high softening temperature and rigidity.

[0056]

[0048] The term “polyester” or “PET”, as used herein, refers to homopolymers and copolymers having recurring ester linkages which may be formed by any method known in the art. Recurring ester linkages may be formed by the reaction of one or more diols with one or more diacids. Non-limiting examples of suitable diols include ethylene glycol, diethylene glycol, 1,3-propanediol, 1 ,4-butanediol, resorcinol, 1,4-cyclohexanedimethanol, 2,2,4,4-tetramethyl- 1 ,3-cyclobutanediol, and polyoxytetramethylene glycol. Non-limiting examples of suitable diacids include terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid, 2,5-furandicarboxylic acid, 1 ,4-cyclohexane dicarboxylic acid, trimellitic anhydride, succinic acid, adipic acid and azelaic acid.

[0049] The term "adhesive layer," such as the adhesive layers 104, 105, refers to a layer or material placed on one or more layers or materials to promote the adhesion of that layer or material to another surface. Preferably, adhesive layers are positioned between two layers of a laminate or film to maintain the two layers in position relative to each other and prevent undesirable delamination. Unless otherwise indicated, an adhesive layer can have any suitable composition that provides a desired level of adhesion with the one or more surfaces in contact with the adhesive layer material. The adhesive for an adhesive layer may comprise any polymer, copolymer or blend of polymers having a polar group thereon, or any other polymer, homopolymer, copolymer or blend of polymers including modified and unmodified polymers, e.g., grafted copolymers, which provide sufficient interlayer adhesion to adjacent layers comprising otherwise nonadhering polymers. The adhesive may include solvent-free adhesives, solvent-borne adhesives, water-soluble adhesives, radiation curable or heat-curable adhesives. Adhesives in the present invention may include coextruded polymeric layers. To enable for high purity of recovered fiber, the adhesive may be a water-sensitive adhesive, a repulpable adhesive, or separated along with the barrier layer 103 during a recycling process and / or repulping process.

[0057]

[0050] The present technology is not to be limited in terms of the particular aspects described in this application, which are intended as single illustrations of individual aspects of the present technology. Many modifications and variations of this present technology can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the present technology, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the present technology. It is to be understood that this present technology is not limited to particular methods, reagents, compounds compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0058]

[0051] The methods illustratively described herein may suitably be practiced in the absence of any element or elements, limitation or limitations, not specifically disclosed herein. Thus, for example, the terms “comprising”, “including,” containing”, etc. shall be read expansively and without limitation. Additionally, the terms and expressions employed herein have been used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof. It is recognized that various modifications are possible within the scope of the disclosure claimed. Thus, it should be understood that although the present disclosure has been specifically disclosed by preferred embodiments and optional features, modification and variation of the disclosure embodied therein herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this disclosure.

[0059]

[0052] The disclosure has been described broadly and generically herein.

[0060] Each of the narrower species and subgeneric groupings falling within the generic disclosure also form part of the methods. This includes the generic description of the methods with a proviso or negative limitation removing any subject matter from the genus, regardless of whether or not the excised material is specifically recited herein. The present technology is not to be limited in terms of the particular embodiments described in this application, which are intended as single illustrations of individual aspects of the present technology. Many modifications and variations of this present technology can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the present technology, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the present technology. It is to be understood that this present technology is not limited to particular methods, reagents, compounds compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0061]

[0053] One skilled in the art readily appreciates that the present disclosure is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. Modifications therein and other uses will occur to those skilled in the art. These modifications are encompassed within the spirit of the disclosure and are defined by the scope of the claims, which set forth non-limiting embodiments of the disclosure.

Claims

What is claimed is:

1. A paper-based recyclable wrapper optimized for recycling that uses an optical sorting process, the paper-based recyclable wrapper comprising: a first paper layer; a barrier layer; a first adhesive layer, the first adhesive layer positioned between the first paper layer and the barrier layer, the first adhesive layer being a partial layer of adhesive; a second paper layer, the second paper layer being a product contact layer having particular use for products having fatty and wet surfaces; a second adhesive layer, the second adhesive layer positioned between the barrier layer and the second paper layer, the second adhesive layer being a partial layer of adhesive; and wherein the paper-based recyclable wrapper has a total fiber content of at least 50% by weight of the paper-based recyclable wrapper.

2. The paper-based recyclable wrapper as in claim 1 , wherein the paper-based recyclable wrapper comprises the barrier layer being a film.

3. The paper-based recyclable wrapper as in any one of claims 1 to 2, wherein the first paper layer is a calendared paper.

4. The paper-based recyclable wrapper as in any one of claims 1 to 3, wherein the second paper layer is a repulpable grease resistant paper.

5. The paper-based recyclable wrapper as in any one of claims 1 to 4, wherein the first paper layer comprises a print layer at a first paper layer first side.

6. The paper-based recyclable wrapper as in any one of claims 1 to 5, wherein the barrier layer is a barrier to water and / or light.

7. The paper-based recyclable wrapper as in claim 6, wherein the barrier layer is metalized.

8. The paper-based recyclable wrapper as in any one of claims 1 to 7, wherein the barrier layer includes polymers comprising PE, PET, PP, or combinations thereof.

9. The paper-based recyclable wrapper as in any one of claims 1 to 8, wherein the first paper layer includes an overlacquer.

10. The paper-based recyclable wrapper as in any one of claims 1 to 9, wherein the first adhesive partial layer and the second adhesive partial layer is a line.11 .The paper-based recyclable wrapper as in any one of claims 1 to 9, wherein the first adhesive partial layer and the second adhesive partial layer is a linear sequence of dots.

12. The paper-based recyclable wrapper as in any one of claims 1 to 11 , wherein the paper-based wrapper has at least 85% fiber by total weight.

13. The paper-based recyclable wrapper as in any one of claims 1 to 12, wherein the paper-based recyclable wrapper is identified as paper on both an exterior surface and an interior surface, and wherein an optical scan of either of the exterior surface or the interior surface is indicated to be paper in a sorting process associated with recycling.

14. A method of producing a paper-based wrapper having at least 50% fiber for use with margarines and butters, the paper-based wrapper having properties to aid in identification of material types during detection in a sorting process during recycling, the method comprising the steps of: providing a first paper layer having a thickness in a range of about30 gsm to 70 gsm, preferably 50 gsm;optionally printing the first paper layer on an exterior side; providing a thin barrier film to provide barrier to water and / or light; conducting a first partial lamination of the first paper layer and the barrier layer by placing an adhesive only in a partial area between the first paper layer opposite the optional print layer and the barrier film to form a first partial laminate; providing a second paper layer having a thickness in a range of about 30 gsm to 60 gsm, preferably 35 gsm; conducting a second partial lamination of the second paper layer to the barrier layer by placing an adhesive only in a partial area between the second paper layer and the barrier layer opposite the first paper layer to form a final laminate; optionally slitting the final laminate to form a plurality of daughter reels.

15. The method as in claim 14, wherein the first partial lamination and the second partial lamination comprises applying the adhesive in a line, a linear sequence of dots, a design, or a combination thereof.

16. The method as in claim 14, wherein the paper-based wrapper has at least 85% fiber by weight.

17. A method of producing a paper-based wrapper having at least 50% paper for use with margarines and butters, the paper-based wrapper having properties to aid in identification of material types during detection in a sorting process during recycling, the method comprising the steps of: providing a first paper layer having a thickness in a range of about 30 gsm to 70 gsm, preferably of about 50 gsm; providing a second paper layer having a thickness in a range of 30 gsmto 60 gsm, preferably of about 35 gsm; conducting an extrusion lamination of the first paper layer and the second paper layer to form a barrier layer between the first paper layer and the second paper layer, with the extrusion forming a complete laminate; optionally printing an exterior surface of the first paper layer of the complete laminate to form a final laminate; and optionally slitting the final laminate to form a plurality of daughter reels.

18. The method as in claim 17, wherein the first paper layer is a calendared paper.

19. The method as in any one of claims 17 to 18, wherein the second paper layer is a grease resistant paper.

20. The method as in any of claims 17 to 19, wherein the extrusion lamination is specifically selected to provide only a light adhesion to the first paper layer and the second paper layer to ensure for repulpability at a recovery rate of fiber in an amount of at least 50%, preferably of about 85%.

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