Integration of new materials in packaging: A Strategic 5-Step approach

Packaging plays a central role in product protection, logistics, and marketing. However, the packaging industry is facing increasing pressure to reduce its environmental impact due to concerns about plastic waste and the depletion of fossil resources. In recent years, the integration of new materials into packaging has become an essential solution to meet sustainability requirements. 

1. New materials in packaging

1.1. Bioplastics

Bioplastics represent a major innovation in the packaging industry. They are made from renewable sources like corn starch, sugarcane, or vegetable oils. Among the most commonly used are PLA (polylactic acid) and PHA (polyhydroxyalkanoates). These materials offer notable environmental benefits, including their biodegradability and reduction of dependence on fossil fuels.

• Advantages: They are biodegradable under certain conditions, and their carbon footprint is lower than that of conventional plastics.
• Applications: Food packaging, plastic films for flexible packaging.
• Limitations: Their cost remains high, and their performance, particularly in terms of oxygen and moisture barriers, may be inferior to that of traditional plastics.

1.2. Recycled materials

The use of recycled materials, such as PET (polyethylene terephthalate), paper, and aluminum, helps reduce waste production and promote the circular economy. Recycled PET, for example, is commonly used to manufacture bottles, food packaging, and everyday consumer products.

• Advantages: These materials reduce waste and save new resources. They also promote the creation of closed life cycles for certain products.
• Examples: Bottles made from recycled PET, cartons made from recycled paper.
• Challenges: The purity of the material is crucial. Contaminants can alter the quality of finished products and make some recycled materials less effective than their new counterparts.

1.3. Bio-based materials

Bio-based materials are derived from natural resources like plant fibers, algae, or starch. They are increasingly used to replace traditional plastics in various sectors, including food and cosmetics.

• Advantages: These materials are renewable and may have a reduced environmental impact compared to petroleum-based plastics.
• Examples: Sugarcane-based packaging, algae used for edible films or cosmetic packaging.
• Challenges: The production cost and availability of these materials may limit their widespread adoption.

1.4. Nanomaterials

Nanomaterials, such as nanoclay or nanocellulose, offer remarkable properties for packaging. They enhance strength, lightweight characteristics, as well as oxygen and moisture barriers, making packaging more effective.

• Advantages: These materials provide a significant improvement in packaging performance, particularly regarding gas barrier properties and mechanical strength.
• Examples of Applications: Films for food packaging with enhanced barriers, smart packaging capable of detecting product freshness.
• Potential Risks: The lack of data on the environmental and health effects of nanomaterials raises concerns, which may hinder their large-scale adoption.

2. Innovations and associated technologies

2.1. Active and intelligent packaging

Intelligent packaging is an emerging technology that improves product preservation through additional functions, such as freshness detection or antimicrobial protection. Active packaging, for example, can release preservatives to extend food shelf life, while intelligent packaging includes sensors capable of detecting changes in temperature or quality.

• Applications: These packages are particularly useful in the food industry for tracking product freshness.
• Examples: Thermochromic indicators on fresh product packaging or antimicrobial packaging to extend food shelf life.

2.2. Compostable and biodegradable packaging

Compostable and biodegradable packaging is designed to decompose quickly under natural conditions or in composting facilities. Compostable packaging, in particular, breaks down without leaving toxic residues.

• Examples: Biodegradable films for fruits and vegetables, compostable coffee capsules.
• Challenges: Composting infrastructure is not yet sufficiently developed in many countries, limiting the effectiveness of these materials at end-of-life.

3. Environmental and economic benefits

3.1. Reducing carbon footprint

Integrating new materials into packaging helps reduce the carbon footprint of the industry. For example, bioplastics derived from renewable sources generally have a significantly lower carbon footprint than traditional plastics. Recycled materials, on the other hand, decrease the need to produce new raw materials.

3.2. Waste management and recyclability

New materials can improve waste management and contribute to higher recycling rates. Packaging made from recycled materials or compostable bioplastics offers interesting solutions to reduce the accumulation of plastic waste in the environment.

• Examples of Improvements: Companies have implemented closed-loop recycling systems, where packaging is continuously recycled and reused.
• Limitations: Recycling rates vary significantly from country to country, and treatment infrastructures for innovative materials are not yet widespread.

3.3. Costs and profitability for businesses

While new materials may incur higher short-term costs, their adoption presents long-term economic benefits. Reducing waste-related costs, enhancing brand image, and adapting to future environmental regulations can offset initial expenses.

4. Challenges and barriers to adoption

4.1. Cost of innovative raw materials

One of the main obstacles to adopting new materials in packaging is cost. Bio-based and recycled materials are often more expensive than traditional plastics due to more complex manufacturing processes and lower production volumes.

4.2. Regulations and standards

The integration of new materials is also hindered by strict and varied regulations across regions. For example, the European Union imposes stringent standards on packaging composition, pushing companies to invest in certifications related to compostability and biodegradability.

• Examples: Regulations on single-use plastics have encouraged many companies to turn to sustainable alternatives, but the compliance process can be lengthy and costly.

4.3. Performance and compatibility issues

Finally, the performance of new materials does not always meet expectations. Bioplastics, for example, may offer inferior mechanical properties compared to conventional plastics, limiting their use in applications requiring high strength.

5. Future perspectives

5.1. Innovations in development

Many innovations are still in development, such as CO₂-derived polymers or next-generation bioplastics that are more efficient and cost-effective. Collaborations between industries and research laboratories are crucial to accelerate these advancements.

5.2. The role of the circular economy

The future of new packaging materials relies on the circular economy, which aims to maximize resource reuse while minimizing waste. Companies are encouraged to rethink their supply chains to include recycled and reusable materials, thereby contributing to a more sustainable economy.