Striking a balance
Paper itself as a product packaging product doesn’t included any mentionable barrier homes, so they require to be constructed by utilizing extra treatments, normally by including barrier finishes either in the paper-making or transforming procedure.
“It’s all about finding the balance between required functionality – both barrier and strength –and guaranteeing a sustainable end of life in existing recycling infrastructure, while passing all the required product safety criteria,” says Janne Varvemaa, Director, Products and Technology at UPM Specialty Papers.
“The solution also needs to be reasonable in terms of total cost of ownership, although consumer preference seems to favour fibre-based packaging, thus creating some top-line growth opportunity.”
Commercialization can likewise show tough, as he explains.
“Pretty much anything is possible on a lab scale, but upscaling solutions that fulfil the functionality and circularity and cost criteria is a key challenge. Sometimes the main challenges and limitations stem from the status quo – it requires effort to challenge the existing packaging and related machinery design as well as barrier requirements that are sometimes over-engineered. Also, regulation is constantly moving, and predictability, as well as reduced complexity, would be needed to set a clear direction for the solution development.”
Christoph Wachter, Director Flexible Packaging Paper Division, Koehler Paper, concurs that plastic composites provide excellent barriers however that these aren’t constantly needed for each item, so it’s important to specify what’s needed. He likewise explains the truth that performance on makers needs to be dealt with.
“The paper without laminates has to run through the same packaging lines as plastic laminates. This is the first major hurdle that can be checked very quickly, even without already knowing which barrier function has to be used. Here it is important to define the necessary functions together and to select a suitable paper or to develop it together.”
From their physical attributes, paper and plastic are rather various products, and the essential distinctions consist of such homes as wetness barrier, stretchability, porosity or sealability, as Eric Valette, Director Innovation BU Flexibles at Coveris, explains.
“This is important when designing the optimal packaging for selected products. That is why switching from plastic to paper is more than just a material change – it pushes the packaging producers to search for a way to close the gap and reach the same functional properties.”
Complementing or changing plastic product packaging
From what our professionals are stating it’s ending up being clear that custom-made options for each item group are the method forward. They concur that there is a function for a variety of various product packaging products, while highlighting the advantages of paper.
Mr Varvemaa explains that both plastic and paper have a function to play in the future – plastics are excellent in regards to performance and flexibility, while paper has an edge in sustainability: it is an eco-friendly basic material and has an internationally wide-spread, well-working recycling facilities, to discuss some sustainability advantages. Sometimes the working service originates from integrating the very best of both products.
“The chosen material needs to fit the purpose of protecting the product. I see many opportunities for increasing the use of paper but ultimately, it’s the brand owners’ commitments and choices that drive the development of packaging,” he includes.
There are 2 primary instructions that have actually been driving the advancement of option, more eco-friendly product packaging products: the requirement to change hard-to-recycle product and the interest in enhancing barrier performance to paper.
“From the perspective of Coveris, it’s not about choosing between paper or plastic, it’s about finding the best, most eco-efficient and best-performing packaging for the respective product – without any limitations in materials,” says Mr Valette.
Mr Wachter sees some constraints for paper, however is positive that the product can play a significant function as main product packaging.
“Paper is a natural product, it will not be able to deliver every barrier. Composite packaging will also continue to exist for certain purposes. When selecting the packaging solution for food, the focus always has to be on protecting the content. There are numerous paper solutions that can be used today on existing packaging lines without sacrificing efficiency. Numerous secondary packaging products made of paper in the food sector are already established in the markets worldwide. The first primary packaging, for example for chocolate or nuts, is currently being launched on the market. We assume that in the near future, the majority of primary packaging will be made of paper.”
Focus on food safety – and browsing the policy jungle
Keeping food safe throughout its journey is of essential value, not just with main product packaging, however likewise with secondary and tertiary product packaging.
“During transport and storage, products require specific protection against potential migration of harmful substances coming from the external packaging. For example, at Coveris we are constantly increasing the usage of recycled material for secondary and tertiary packaging which is best practice for the environment. But these materials are not suitable for direct food contact and do not ensure a natural barrier against e.g. mineral oils (MOAH and MOSH). As a result, we need to make sure the primary packaging provides a proper barrier against migration from recycled content materials, and corrugated cardboard which is used for secondary or tertiary packaging,” includes Mr Valette.
Diverging policies for recyclability and food contact in various nations can show tough, as can an absence of meaning of what paper recyclability indicates.
“There is not yet a unique method to assess the recyclability of paper, and no harmonized regulation to demand it, even in the EU. Most of the time the packaging is designed to be launched in several countries at the same time and the main challenge is to make sure the solution fulfils individual regional recycling requirements,” state Mr Valette.
A significant difficulty when establishing brand-new barrier ideas is the policy of the various nations with regard to the active ingredients of items that enter into direct contact with food, in addition to specific requirements from big business and corporation, as Mr Wachter explains.
“It is important that the barriers that we develop do not affect the recyclability of the paper, because that is the main argument for the material. When it comes to our flexible packaging solutions, we speak of ‘100% paper’ because only a dispersion is applied during paper production. It fulfils the barrier function, but is not made of PVC, PVDC or a conventional laminate and is harmless for direct contact with food.”
Mr Varvemaa includes that recyclability as an end-of-life service for oily and wet foods can be challenging due to food residues. In these kinds of applications composting would be the most possible sustainable end-of-life service.
“Non-food applications are easier, although naturally there is certain regulation (e.g. toys) that needs to be taken into account in product design. Otherwise, similar design criteria exist: balancing functionality, circularity, and financial feasibility.”
He concurs that the absence of an international recyclability standard triggers obstacles.
“Initiatives such as 4evergreen are working hard to create certification systems that cover wide geographic areas and consider the development of novel packaging solutions and the changing composition of recycled paper and board streams, as consumption of newspapers, magazines and other printing papers is declining.”
Potential for the future
Asked about advancement capacity for paper product packaging, Mr Wachter highlights the truth that a barrier principle versus oxygen, saturated and fragrant hydrocarbons and grease has actually been established and is already on the marketplace, which dry and oily filling items such as chocolate or muesli for that reason present no issue.
“However, liquids cannot yet be packaged with it. In 2023, we want to introduce a water vapour barrier to the market. This could also be used to pack products such as washing powder or pet food in paper. Various market tests are already underway. The further development of dispersions is aimed at barriers made from bio-based and renewable raw materials.”
Mr Valette sees significant development opportunities for paper product packaging.
“Following the market’s demand and global packaging directives, paper packaging is expected to grow further. According to latest research, it will steadily grow by 3.5% and by 2027 it will reach a market value of 493,5 billion USD, according to recent market studies. Our newly created Paper Business Unit already accounts for 30% of total group sales, which confirms this trend.”
In conclusion, Mr Varvemaa highlights the value of partnership to accomplish critical sustainability objectives, which needs openness, dexterity and dealing with brand-new kinds of partners.
“As an optimist, I would say imagination, or perhaps the lack of it, sets the limits. It’s been shown that even the highest barrier requirements can be achieved with recyclable solutions and creating packaging designs that utilize this opportunity as a complete or partial solution is now possible. In my opinion, a perfect drop-in solution to replace plastic with a paper-based solution rarely exists, so co-creation is key.”
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