Function, design, circularity

Packaging is the visible and tangible expression of the product - and increasingly a criterion in purchasing decisions. This is evidenced by the results of a study by the industry association Pro Carton from this year. According to this, 57% of more than 5,000 respondents from five European countries stated that a sustainable lifestyle has become more important to them. The choice of the "right" packaging plays an important role in this. Every second respondent said that they do indeed consider at the point of sale to what extent their purchasing decision impacts the environment. After all, 40% said they had switched brands or products in the past twelve months because they had concerns about the packaging. The reasons for this were "non-recyclable packaging" (54%), followed by "unnecessary additional packaging" (37%) and "plastic packaging" (31%). The latter reason has more to do with the general image of the material than with its fundamental functionality and recyclability. According to data from the Federal Environment Agency, the largest share of food packaging in Germany is currently made of plastic (about 65%), followed by paper and cardboard (around 25%). Bioplastics and alternative materials currently play only a minor role (under 5%), but are increasingly being tested for special applications.

Retail chains are rethinking

And who is being called upon to ensure more sustainability? 57% of the study participants cited manufacturers, 21% consumers, 14% the government, and only 8% the trade. Nevertheless, retail companies are under massive pressure. For the food retail sector, packaging is a direct link between brand image and environmental protection promises. Retail chains like Aldi, Lidl, or Kaufland have set ambitious goals: about 100% recyclable packaging for private labels by 2025 or a reduction of plastic by 20% to 30% in the same period. Large retail companies like the Schwarz Group (Kaufland, Lidl) have been experimenting with other materials for years, including Silphie, when it comes to packaging, among other things, for food. Consumer criticism is mainly directed against the use of plastic. The discussion is also fueled by study results like those from DS Smith. For the survey "Material Change Index," commissioned by the manufacturer of sustainable, fiber-based packaging solutions, 1,500 food items from the supermarket were examined. Conclusion: For many foods and beverages, which are predominantly packaged in plastic, this can be removed or replaced by alternatives. In Germany, according to DS Smith, this plastic mountain amounts to 38.6 billion avoidable pieces per year. Meat and fish (84%), dairy products (83%), and non-alcoholic beverages (80%) top the list of categories with the largest share of plastic packaging.

Packaging manufacturers seek solutions

In the packaging industry, sustainability is no longer a niche topic but a central innovation agenda. According to the "Sustainability Trends Report" by the European Packaging Institutes Consortium (Epic) from 2024, over 75% of packaging manufacturers are specifically investing in sustainable material developments, new manufacturing processes, or digital tracking systems. The challenge is complex: packaging must ensure protection and durability. Besides that, they must be machine-compatible, comply with legal requirements, and at the same time be recyclable, resource-efficient, and produced with as little CO_₂ as possible. Often the biggest hurdles to overcome when it comes to new materials are scalability and price. The packaging market is very price-sensitive. There is no shortage of examples of interesting approaches, both from established manufacturers like Metsä Board or Alpla and from newcomers. There are also impulses from research. Those who want to learn about environmentally friendly materials: The Frankfurt agency Milk Food & Design has released a nicely designed booklet titled "Future Packaging Material" in its third edition. Through the agency's website, you can also access an online glossary.

Material reduction through smarter design

The first and simplest lever for more sustainable packaging is the reduction of the material used. Through so-called "lightweighting" concepts, significant savings can be achieved with films, bottles, or cups - without compromising the protective function. A few months ago, Diageo presented an especially lightweight glass bottle for the Johnnie Walker brand.

 With a volume of 70 cl, the bottle weighs only 180 g without the cap. A study cited by British Glass shows that every gram of glass saved leads to a reduction of over half a gram of CO₂ emissions during production. An extreme example. But throughout the industry, ways and methods are being researched to save as much material as possible. In general, a PET bottle can be produced with up to 30% less material than ten years ago, without losing stability. The use of so-called "sleeve-free designs" for beverages or labels with reduced adhesive application also helps to facilitate recycling. The solution from Vilsa-Mineralbrunnen also falls into the "material reduction" category. The company dispenses with the usual shrink film for its single-use bottles made of rPET, which are offered as six-packs. They are now held together by selective, very strong adhesive points. A solution developed by the KHS Group.

Plastic packaging: Monomaterial instead of composite

Plastics remain indispensable in many food applications for functional reasons. Their advantage lies in the high protective function with relatively low material usage. The challenge is in designing recyclable solutions. Black plastics or multilayer films are difficult to detect or sort. However, advances in detection technology, such as through digital watermarks, and the introduction of minimum recycling quotas are driving improvements in recyclability. A key advancement is the shift from multilayer, hard-to-separate composite packaging to pure monomaterials. Packaging made from pure polypropylene (PP) or polyethylene (PE) can be better detected, sorted, and processed in the existing recycling system. Advances in barrier layers now make it possible to use monomaterials even for products with high protection requirements - such as fatty or moisture-sensitive foods. Numerous manufacturers now label their packaging with the "Design for Recycling" label to provide consumers with guidance. Nestlé, for example, has moved away from composite films made of various materials in favor of a monomaterial solution for its soup and sauce pouches.

Bioplastics: Between hope and reality

Bio-based plastics like bio-PE or PLA promise a reduction in fossil resources. However, their environmental balance heavily depends on the context of their application. Biodegradable plastics often do not decompose in industrial composting facilities because the retention time is too short. Additionally, they can disrupt plastic recycling if mistakenly placed in the yellow bag. In contrast, bio-based but recyclable materials like bio-PET or bio-PE are considered viable alternatives when integrated into existing recycling streams.

Fiber-based: Paper and cardboard

Paper and cardboard packaging are generally considered environmentally friendly as they are based on renewable raw materials and are well integrated into the existing waste paper recycling system. However, they lose functionality with fatty or moisture-rich foods. To still achieve a protective effect, plastic coatings are often used, which, however, make recycling difficult or impossible. New developments

 work with water-soluble or biodegradable barrier coatings that aim to maintain recyclability. The coating of paper must not exceed 5% of the total weight for the paper to be considered homogeneous and EU-compliant for recycling. Additionally, the coating should be water-soluble, biodegradable, and unproblematic in the recycling process to ensure actual recyclability. Tests with new coatings have shown that a coating layer of 2.5% and less can be sufficient. Unsurprisingly, more and more food manufacturers are switching to paper-based packaging. For example, Milka has tested a new paper packaging for its tablet portfolio. It is made from FSC-certified paper with minimal coating. This allows the packaging to be disposed of via the paper bin and subsequently recycled. Another example: Masterfoods is testing recyclable tomato sauce single packages made of paper in Australia: with 58% less plastic than the original packaging.

New alternative molded fiber

Molded fiber as a packaging material has proven itself. However, the recyclable material was long used primarily for transport and outer packaging. In the food sector, it played a minor role, apart from the well-known egg cartons. This is changing rapidly. Companies like Papacks are committed to establishing molded fiber as an ecologically safe alternative to plastic and glass. Thanks to new barrier technologies and raw material processing, processing possibilities have massively increased. An interesting example is the paper bottle from Paboco with a fiber-based closure from Blue Ocean Closures. The bottle weighs less than 16 g in total, while the barrier made of high-density polyethylene (HDPE) accounts for less than 2 g. But Papacks also has a bottle in its program that is 100% made of molded fiber and, thanks to a plant-based coating, is versatile.

Reusable systems in stationary and digital trade

The systemic shift towards a circular economy is particularly evident in the reuse of packaging. Reusable cups for coffee, reusable take-away containers, deposit systems for yogurt jars, or sturdy shipping boxes for online retail are gaining acceptance. The willingness and the number of users and system providers are growing. For example, the mail-order pharmacy Doc Morris is testing the use of reusable packaging. The cooperation partner is Ravioli in Hamburg. Pricon GmbH, a wholesaler for optical specialty stores, has recently started using reusable shipping packaging from Hey Circle to reduce waste and CO₂ emissions. Snack producer Seeberger is introducing reusable cups at the point of sale. Particularly promising are reusable solutions that use an existing return infrastructure, such as Sykell, whose boxes and cups made of PP can be easily returned via reverse vending machines. Functioning deposit or collection systems, combined with increased consumer awareness of packaging waste, significantly improve the recycling and waste situation. Even when it comes to plastic. The "disposable product" is increasingly being perceived as an important resource.