Over €100 Million Poured into Packaging Innovation at FACHPACK 2025
Constantia Flexibles kicked off 2025 with key milestones: acquiring Aluflexpack, expanding its product portfolio, and launching digital printing in Denmark. Its Low Carbon Aluminum Product Carbon Footprint (PCF) calculation has been validated by TÜV Süd. Visit booth 4-523 to explore the company’s innovations.
Constantia Flexibles, the world’s third-largest producer of flexible packaging, enters FACHPACK 2025 following a period of strategic investment, technological advancement, and portfolio expansion, reinforcing its position in premium flexible packaging and sustainability leadership.
Earlier this year, Constantia Flexibles completed the acquisition of Aluflexpack, a leading European supplier of customized flexible packaging solutions. This move significantly strengthens Constantia Flexibles’ footprint in high-value segments, particularly in the food and pharmaceutical industries, while enhancing its technological capabilities and regional production reach.
“We have entered 2025 with a clear focus on delivering flexible packaging ready for tomorrow’s challenges,” said Marc Rademacher, Executive Vice President Consumer Commercial at Constantia Flexibles. “The acquisition of Aluflexpack and our investments across our production plants are not just about growth—they are about creating an agile, future-ready packaging network that serves our customers with greater speed, technical depth, and environmental responsibility.”
With this new addition to the Group, Constantia Flexibles is proud to showcase an expanded product portfolio at FACHPACK 2025 in Nuremberg, September 23-25 at booth 4-523, where it will present a range of innovations, including its Ecolutions portfolio, advanced pouch solutions, and new lidding materials. Constantia Flexibles and Syntegon will jointly present pouches produced on Syntegon’s PMX line to showcase the advanced real-world performance of Constantia Flexibles’ mono-materials EcoLamHighPlus (mono-polyethylene) and EcoVerHighPlus (mono-polypropylene)—for these packaging formats. Constantia Flexibles will also show EcoVerHighPlus in a collaboration with machine builder Wolf Verpackungsmaschinen, featuring a live demonstration at booth 1-428.
Over 100 million invested in global facilities
Constantia Flexibles has committed over 100 million to upgrading its global production network. In Austria, 50 million has been invested in expanding the rolling mill at the Constantia Teich plant, increasing aluminum foil production by around 30 percent up to 90,000 tons annually. An additional 30 million has been allocated to a new lacquering line. In Germany, Constantia Flexibles has invested more than 6 million in a new machine-direct orientation (MDO) line at its Constantia Pirk facility. This advanced line supports the production of EcoLamHighPlus. In Spain, the Burgos plant of Constantia Tobepal has been enhanced with over 15 million for a tandem extruder, increasing capacity and providing a reliable backup for the Logroño site. Meanwhile, in Mexico, the company has invested significantly into the Constantia Aluprint plant to improve speed, reliability, and efficiency.
Digital Printing: Ready to meet the demands of customization and speed
A major technology milestone has been reached with the installation of a state-of-the-art digital printing line at the company’s site in Copenhagen. This industry-first solution allows water-based, full-surface digital printing on aluminum and PET substrates. The system eliminates the need for clichés or plates, enabling rapid design-to-print turnaround while covering 93 percent of Pantone colors. It also allows mass customization while reducing waste.
Low Carbon Aluminum: Product Carbon Footprint calculation methodology validated by TÜV Süd
Further reinforcing its environmental commitment, Constantia Flexibles has received third-party validation from TÜV SÜD for its Product Carbon Footprint (PCF) calculation methodology for Low Carbon Aluminum. It ensures the accuracy and transparency of carbon footprint data across the value chain, empowering customers to make informed, measurable progress towards their own sustainability targets.
HIGHLIGHT PRODUCTS AT FACHPACK 2025
Live at FACHPACK: Ecolutions range for a circular economy
At FACHPACK 2025, the company will spotlight its Ecolutions range, which offers a comprehensive selection of mono-material packaging Designed for Recycling. The portfolio includes EcoLam, a family of PE-based laminates designed for the PE recycling stream, available in multiple barrier levels including EcoLamHighPlus, which rivals traditional PET/Alu/PE structures. EcoVer, based on mono-PP, delivers excellent clarity, heat resistance, and sealing performance, making it ideal for a wide range of applications. Complementing these is EcoAlu, featuring lightweight aluminum-based solutions like AluTainerRetort, which provides high barrier protection for demanding uses such as retortable food packaging.
LEADING THE LIDDING BUSINESS
ComforLid: The new standard for aluminum die-cut lids
Constantia Flexibles is redefining convenience and sustainability with ComforLid – an innovative aluminum lid that combines hygiene, recyclability, and reduced CO₂ emissions. Designed with consumer convenience in mind, ComforLid replaces traditional plastic lids while maintaining ease of use and improving environmental impact. Its optimized material composition ensures full recyclability via existing systems, while upcoming production with Low Carbon Aluminum will cut greenhouse gas emissions by up to 43 percent. With integrated drinking functionality and broad application potential, ComforLid sets a new standard for future-ready packaging.
EcoPeelCover: The thinnest aluminum lid in the Ecolutions family
In addition to ComforLid, Constantia Flexibles has developed another aluminum lid focused on resource conservation: EcoPeelCover, the world’s thinnest die-cut aluminum lid of its kind. It significantly reduces material usage—by 25 percent in aluminum thickness and 50 percent in coating weight. Printing is done solvent-free using the UV flexographic printing process.
Despite its ultra-thin structure, the lid meets high-performance standards: it is puncture-resistant, provides reliable protection against oxygen and moisture, and withstands sealing temperatures of up to 230°C. As part of the Ecolutions product family, it is also available in Low Carbon Aluminum variants and with ASI certification.
This specification has been recognized with top industry honors, winning the prestigious German Packaging Award in 2024 and the Global Packaging Award in 2025.
CONSTANTIA FLEXIBLES EXPANDS POUCH PORTFOLIO
Smart design meets real-world functionality: The versatile pouch portfolio
Following the integrationwith Aluflexpack, Constantia Flexibles is elevating its pouch portfolio—offering smart, high-performance packaging for food, pet food, dairy, confectionery, and pharma. Thanks to a fully integrated production process, including film manufacturing and pouch forming with features like zippers or spouts, customers benefit from faster lead times, tailored solutions, and consistent quality. Available in various shapes, sizes, and materials, these pouches also feature advanced printing and customizable options, making them ideal for diverse market needs.
EcoVer Spouted Pouch – premade pouch with and without spout: A PP-based packaging innovation
A recent highlight is the launch of the mono PP spouted pouch—a fully aluminum-free solution that is Designed for Recycling in the respective recycling stream. This innovative pouch offers exceptional oxygen and water vapor barrier properties, making it ideal for shelf-stable products that undergo hot-filling and pasteurization, such as baby food, fruit purée, and wet pet food, as well as for cold-filled or dairy applications. The spouted pouch is available in three different barrier grades: EcoVer, EcoVerPlus, and EcoVerHighPlus.
EcoVer Retort Pouch: PP-based mono-material retort pouch for wet pet food and ready-made meals
A major innovation in pouch packaging is the new retortable mono PP pouch, engineered for high-heat applications like wet pet food and ready meals. This high barrier solution withstands retort processing while aligning with European PP recycling streams. EcoVer Retort Pouch offers high oxygen and moisture barriers, ensuring product safety and shelf life, and provides a Designed for Recycling alternative to traditional multi-material laminates.
HIGH-PERFORMANCE ALUMINUM SOLUTIONS FOR WET, DRY, AND RETORT APPLICATIONS
Alufoil Container: A smart choice for wet and preserved food applications
In addition to its pouch solutions, Constantia Flexibles offers high-performance Alufoil Containers, ideal for applications such as meat, fish, ready meals, desserts, and pet care. Engineered to meet the highest performance and quality standards, these containers leverage the functional benefits of aluminum, including direct food contact suitability at high temperatures and exceptional barrier protection at minimal thickness. With fully customizable material specifications, creative shaping options for brand differentiation, and full-surface printability, the Alufoil Container delivers both technical excellence and strong shelf appeal.
Foil for peel-off end: For retort and dry applications
Also new in the portfolio of Constantia Flexibles is a premium peel-off foil solution from Aluflexpack, designed to deliver high-performance barrier protection alongside effortless consumer convenience. Suitable for both retort and dry applications, the foil withstands high temperatures and pressure during sterilization, making it ideal for food, pet food, pharmaceuticals, dairy powders, snacks, and supplements. It ensures long-lasting freshness and a clean, easy-open experience. Fully customizable, it adapts to diverse packaging needs across industries
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