Fiber-based frenzy: Renewable packaging elevates brands amid plastic reduction goals

05 Apr 2022 --- Fast-paced innovation in fiber-based packaging is creating opportunities for brands and retailers to switch from fossil fuel-based rigid and flexible plastic packaging formats to renewable alternatives. 

However, matching plastic packaging’s functionality, protection and shelf life with fiber-based solutions presents significant challenges. These challenges are driving innovation in materials and coatings, enabling certain applications to compete with plastic packaging.

PackagingInsights discusses fiber-based packaging trends with Daniel Frey, head of innovation at Huhtamaki Fiber Foodservice Europe-Asia-Oceania, and Will Mercer, R&D director for the Paper Business Unit at Coveris.

Fiber-based innovation
Frey says that brands and packaging providers are increasingly focused on fiber-based solutions to decrease fossil fuel-based plastic reliance as consumers lose patience with plastic pollution.

According to Innova Market Insights, a majority of global consumers perceive paper-based packaging as being “somewhat environmentally sustainable” (37%) (plastic packaging (31%)) or “very environmentally sustainable” (35%) (plastic packaging (15%)).

“The key developments in fiber packaging innovation include material and manufacturing,” explains Frey. “On the material front, solutions now include a wide range of options from 100% fiber-based products to products that increase fiber use and reduce plastic use in packaging.”A fiber lid may seem a simple product but is complex to make while ensuring functionality, says Frey.

“On the manufacturing front, we have smooth and rough molded fiber products and have also seen an emerging interest in the use and application of dry molded fiber technology.”

Meanwhile, Mercer highlights opportunities for brands to switch to cartonboard tray formats compatible with lidding film or recycled PET lids. Coveris has developed a sandwich skillet branded RecyclaPaper boasting good product visibility through a paper-based liner. Also, its PaperBarrier Seal offers an alternative to plastic film in various formats, such as FFS and bags.

“A critical trend in delivering circularity in fiber-based solutions is ensuring the new product is designed for recyclability and circularity, thereby maximizing fiber yield recovery through the recycling process,” he notes.

Overcoming challenges
Plastic packaging for food provides many benefits such as safety, protection, shelf life, performance, product visibility and functionality. Mercer points out that while not all of these attributes can be achieved with fiber-based packaging, material and coating innovation has allowed Coveris to explore plastic replacements for specific applications.

“It is an exciting period of development for fiber-based solutions, and the main challenge is replicating performance characteristics while maintaining recyclability and circularity with a technically very different substrate,” he says.

Coveris’ RecyclaPaper sandwich skillet is a monomaterial solution featuring a paper-based translucent window in a fully lined pack instead of a typical plastic liner. Meanwhile, the PaperBarrier Seal, developed in partnership with Brigl & Bergmeister, offers a paper alternative with barrier properties against moisture, oxygen, grease and mineral oil for long shelf life products.Coveris’ ClipLid Board Tray used for sushi.

Fiber-based alternatives for food packaging require a high level of expertise and innovation due to the complexity in achieving the necessary manufacturing and material innovation, adds Frey.

“A fiber lid used for beverage cups may seem to be a simple product but is quite complex to make while ensuring perfect functionality like lid fit and performance. We continue to focus our product development efforts to provide solutions to our customers for their needs and have increased our manufacturing footprint within Europe for smooth molded fiber products.” 

“The other challenge is to ensure functionality for use cases such as moisture proofing, strength, high temperatures and shelf life. This challenge requires close collaboration with leading foodservice and FMCG brands to understand performance needs and develop solutions meeting the highest quality standards.”

For example, Huhtamaki collaborated with McDonald’s on its Sundae cup and lid, which is 100% plastic-free and made with fibers.

LCA guidance
As a multi-platform packaging manufacturer of flexible plastic and paper-based solutions, Coveris is well-positioned to help its customers optimize their packaging selection for the specific needs of their products, environmental aims and business values.

“With different performance and functional features and the availability of life cycle assessment (LCA) tools, we can make better-informed decisions about the overall environmental impact, including maintaining or improving the shelf life performance of the packaged product, with sometimes surprising results for our customers,” continues Mercer.

“Exploring the full life cycle of packaging from its sourcing to end-of-life is a powerful tool as we move to a more [environmentally] sustainable future, aligned with our vision for No Waste.”The key developments in fiber packaging innovation include material and manufacturing, says Frey.

Coveris is increasing its focus on paper packaging solutions but has no intention of withdrawing from the plastics packaging segment, CEO Jakob A. Mosser recently announced. The European packaging manufacturer is primarily known for its plastic packaging and film products.

However, Frey argues that the science-based evidence, such as LCA studies, has shown paper-based food packaging to have a significantly lower impact on the environment when compared to reusable alternatives in quick-service restaurants.

COVID considerations
Concern over potential COVID-19 contamination reinforced the focus on packaging’s protective role. “Food packaging can help address the need for hygienic options, and consumers have started to understand this better,” says Frey. “Brands are also focusing on reducing fears around hygiene. One example is the advent of cutlery given in separate paper packaging.”

The pandemic initially saw a spike in demand for rough molded fiber products, such as egg cartons and fruit trays, in line with the increased demand for food products at retail, adds Frey.

“With home delivery and takeaway becoming extremely popular, there is now a focus on providing fiber-based packaging innovation solutions for a more diverse set of use cases within food delivery. The return from lockdowns and continuing focus on reducing the use of plastics has continued as foodservice businesses return to normalcy.”Coveris’ is a monomaterial sandwich skillet featuring a paper-based translucent window.

Meanwhile, a significant amount of Coveris’ packaging is for markets deemed essential during the COVID period, including food and beverage, home and personal care, diagnostics and medical.

“It was therefore important we maintained supply continuity of packaging for these products. As a result, some innovation projects and new launches using fiber-based materials were delayed,” says Mercer. “We are now back on track with development projects.”

Bigger problems
Paper has a well-established recycling infrastructure, including kerbside collection in most local authorities, adds Mercer. “However, as we have seen in the case of plastics, designing for maximum fiber recovery through the recycling infrastructure is critical in continuing to grow the recovery rates and not damage them through ill-thought-out packaging design.”

“Food waste is well known to be a significantly bigger issue than packaging waste, whether this is conventional plastic or fiber, therefore maximizing the utilization of our expertise in both material development and food science to deliver circularity, functionality and product protection in our solutions is paramount,” he concludes.

By Joshua Poole