Global research uncovers quality control difficulties in shift to environmental packaging

11 Mar 2022 --- A majority of packaging professionals say the quality control processes for environmentally sustainable packaging materials are more difficult than conventional materials, according to international research by Industrial Physics. 

The global testing and inspection company for packaging, products and materials conducted research among 225 packaging professionals. Nearly three-quarters of the companies surveyed (71%) report that they experience the quality control processes for environmentally sustainable packaging materials as “significantly more difficult” or “somewhat more difficult.”

Nearly half of these companies (49%) cite meeting testing standards as one of the biggest challenges they face in the wider adoption of environmentally sustainable packaging materials.

The Sustainable Packaging Research Survey also revealed that respondents believe that new standards (52.5%) and new regulatory requirements (41.6%) will impact innovation in environmentally sustainable packaging most over the next five years.

The findings show that paper, cardboard and plant-based, biodegradable flexible fiberboard packaging, along with synthetic biodegradable packaging, are the most commonly used materials to replace less environmentally sustainable alternatives such as plastic, paper and film.

These findings are no surprise to Greg Wright, global vice president of sales and marketing at Industrial Physics. He explains: “[Environmentally] sustainable packaging means the use of completely new materials for which accepted testing methods may not yet be available. The processes are constantly evolving, and our expertise in testing the integrity of packaging, products and materials means we can guide manufacturers through the transition.”Paper and cardboard were among the most commonly used materials to replace less environmentally sustainable materials.

Transitional challenges
The survey found that 69% of respondents cite “cost” as the most important challenge in the supply chain. Industrial Physics says global supply blockades caused by the pandemic have made supply more difficult, and the aftermath is still struggling. This issue means that multiple suppliers are often needed instead of one reliable supplier, putting extra pressure on the quality control processes and making testing for packaging integrity more critical.

The questionnaire showed that most companies are actively looking for environmentally sustainable packaging solutions, but encounter a whole series of additional challenges.

Challenges include optimizing material performance in the protection of goods (53%), passing on the increased material costs to the customer (50%), and being able to meet safety and testing standards (49%).

“Our customers are trying to find the right standards and how to test against those standards,” says Joshua Miller, a product manager at Industrial Physics. “We can help customers shape their tests, for example, by giving them a better way to test a product. As a result, they get better data that still meet internal standards.”

Future-proof testing
The research offers a glimpse into the future of environmentally sustainable packaging and explores the adjustments that manufacturers and the sector will have to make to realize the innovation in and implementation of environmentally sustainable packaging materials.Some 69% of respondents cited “cost” as the most important challenge in the supply chain.

“This [set of challenges] is what testing is for, and why manufacturers need to test. It’s about being able to confirm that the physical properties, whether that’s strength, leak resistance, lifetime prediction, recyclability or anything else, can meet the standards for performance and durability,” says Sean Kohl, global line product director at Industrial Physics.

The survey results involved organizations around the world, including companies with more than £1 billion (US1.31 billion) in revenue. The research follows the introduction of the extended producer responsibility and other legislation in the UK, Europe and the US, which tax plastic packaging items made, imported or re-exported that contain less than 30% recycled plastic.

“Our research shows that manufacturers face a variety of risks. However, these risks can be identified and reduced by working with a partner for testing and integrity solutions for packaging,” concludes Jim Neville, Industrial Physics’ CEO.

Industrial Physics offers a wide range of testing solutions for the integrity of packaging, products and materials for the food, flexible packaging, medical, pharmaceutical, and coatings sectors. 

The full results are presented in Industrial Physics’ Sustainable Packaging Research Report published on March 8, 2022.

By Joshua Poole