Henkel Develops Heat-Seal Coating for Right-Sized Paper Mailers in E-Commerce
Aquence HS 2819 RE is designed to support automated paper packaging production, secure sealing and recycling-compatible e-commerce shipping solutions.
Paper-based mailing envelopes are gaining importance in e-commerce as lightweight, flexible and durable packaging alternatives. Henkel Adhesive Technologies has developed Aquence HS 2819 RE, a water-based heat-seal coating designed to enable secure sealing of paper mailers while supporting recycling compatibility and automated packaging processes.
Right-sized packaging gains importance in e-commerce
Traditionally, pre-formed cardboard boxes and envelopes have been widely used for e-commerce shipments. However, companies are increasingly adopting right-sized packaging, particularly in automated fulfilment operations, where packaging is tailored to the dimensions of individual products rather than selected from predefined sizes.
Paper mailers made from heat-sealable roll stock support this approach. The packaging manufacturer applies the coating to high-strength kraft paper, allowing e-commerce companies to produce envelopes directly from rolls through automated processes. The paper is cut to match the product's dimensions and sealed using heat.
This process helps reduce empty space, packaging material consumption and overall shipment weight while supporting logistics efficiency.
Paper-based mailing envelopes are particularly relevant to the fashion industry, which accounts for more than half of global demand for flexible e-commerce packaging. They are also used to ship electronic products, toys and other product categories.
Paper mailers and upcoming packaging regulations
Paper mailers are also gaining attention in the context of packaging regulations. Their structural design makes them suitable for addressing the Packaging and Packaging Waste Regulation (PPWR) requirements relating to recyclability and minimising empty space in packaging, which will take effect in 2030.
Paper is also among the most frequently recycled packaging materials in Europe, making it an option for e-commerce shipping solutions focused on material recovery.
Aquence HS 2819 RE: Coating for automated sealing
Henkel's Aquence HS 2819 RE is a water-based heat-seal coating developed for paper-based mailing envelopes. According to the company, it consists solely of ingredients classified as harmless and is free of mineral oils and CMR substances.
Under specified conditions, the coating meets the requirements of FDA and EU regulations, as well as the recommendations of the German Federal Institute for Risk Assessment (BfR) for food packaging. Its recyclability has been confirmed by accredited testing institutes.
The coating is designed to provide reliable sealing and stable processing on flexographic and rotogravure printing presses, including at high speeds.
Dr. Arianna Savini, Market Strategy Manager Europe Paper Packaging at Henkel, said: “Sustainability and performance are not mutually exclusive in packaging technology; they are interdependent. With Aquence HS 2819 RE, paper mailers can be optimized to meet the demands of modern e-commerce. This enables automated right-sizing processes without compromising recyclability or functionality. The coating runs stably on flexographic and rotogravure printing presses, even at high speeds. As a platform technology, it is also suitable for other paper-based applications, such as food packaging, industrial bags, and hygiene products."
Henkel releases white paper on right-sized paper mailers
Henkel has also published a white paper titled “Beyond the Box: Unlocking Right-Sized Paper Mailers in E-Commerce.”
The publication examines how automated packaging systems and paper-based shipping envelopes can work together to improve efficiency and sustainability in e-commerce. It also discusses the role of heat-seal coatings in producing right-sized shipping packaging and the requirements of future regulatory frameworks.
The white paper is available at: https://next.henkel-adhesives.com/us/en/white-papers/still-shipping-air-in-your-boxes.html
AQUENCE® is a registered trademark of Henkel and/or its affiliates in the USA, Germany and elsewhere.