Paper packaging combats climate change but requires capacity investment, says Walki’s head of sales

14 Jul 2022 --- Walki has expanded its paper-based packaging solutions with the addition of printable drinking straws and recyclable materials for frozen foods. Dudley Jones, head of sales for converted products, tells PackagingInsights that paper packaging can help fight climate change but faces material cost and availability challenges. 

Jones highlights that European forests are growing and represent a huge non-fossil-based and renewable resource. “Well-managed forests can actually maximize CO2 uptake since a growing tree takes in more carbon – an old tree just stores carbon,” he explains.

“We can also do other things with forestry by-products. For example, Tall Oil is a derivative of the paper-making process from pine trees and can be synthesized to make PE resin from a non-fossil fuel-based source.”

However, paper is currently less available and more costly than plastic due to supply constraints, rising energy costs and work-to-rule issues that have caused allocation issues, he adds.

“It is critical that the paper industry invests in capacity to meet the growing demand for paper-based packaging. It’s always the economics questions: paper is more expensive than plastics, but people want paper because there’s a recyclable stream already in place.”

Printable straw pioneers
Plastic straws are banned or in the process of being phased out in several parts of the world. In the EU, the Single Use Plastics Directive is in effect, forcing brand owners to switch to fiber-based alternatives.

Jones says there have been some quality challenges with the current paper straw alternatives on the market as they tend to get soggy in hot drinks, making them not only unpleasant to use but also dangerous for children.Jones showcases “WalkiStraw” at Packaging Innovations 2022 in the UK.

Walki has invested in the Finnish start-up Dolea to produce recyclable and printable paper straws in Finland and the UK. Dolea’s straw uses 25% less material and stays intact in all drinks, including hot beverages. Walki will also sell the straws in the UK under its own brand, “WalkiStraw.”

“As the straw is certified as paper according to PAP21, there is no need for special handling in the recycling process, meaning that the straws are fully recyclable. As the straw also has excellent printability, customers can brand their straws with logos,” notes Jones.

“‘WalkiStraw’ is not spirally wound or glued but dispersion-coated board formed into a straw, which provides several advantages: it doesn’t degrade or give off tastes and is great for recycling.”

Recyclability for frozen foods
Walki has also expanded its materials portfolio to meet the rising demand for frozen food packaging that can be recycled through paper streams. “Walki Evo Seal” and “Walki Opti Seal” are paper-based packaging for frozen pillow pouches. Meanwhile, “Walki Pack Tray” is a board-based tray for frozen ready-meals, designed to replace aluminum, plastic or plastic-coated trays.

“Frozen food is an ideal way to prolong shelf life without losing out on the vitamins. It is also an excellent way to combat food waste. This is important as up to 9% of global carbon emissions can be attributed to food waste, especially fruit and vegetables,” says Jones.European forests are expanding, while growing trees help maximize CO2 absorption.

“Frozen food places high demands on the packaging. It needs to be both sturdy and puncture-resistant to handle diverse situations like pressures of sealing and mechanical tear during transportation. The packaging also needs to withstand variability in temperatures as some frozen food is defrosted in its packaging.”

“Walki Evo Seal’s” dispersion coating makes it recyclable in the waste-paper stream without any separation process, while its minimized PE-coating makes it suitable for recycling with paper with an acceptable fiber yield.

Meanwhile, “Walki Pack Tray” is easy to fill, transport, store and safe to use in microwaves and conventional ovens up to 220 degrees for up to 60 minutes. The tray material is PET-free and recyclable in the paper stream.

Barriers to high barrier
Historically, Walki builds barrier and functionality onto paper and board it has purchased by utilizing extrusion and dispersion coating-lamination technologies. However, the company believes both plastic and paper will be integral to the circular economy for packaging.

It also offers mono-PE laminates, accredited compostable and post-consumer recycled (PCR) materials and the capability to print both plastic and paper materials. It acquired two companies that produce biodegradable waste bags, carrier bags with PCR content and mono-PE laminates.

Jones says it is especially important to continue developing circular plastic packaging as higher barrier technology for paper packaging has not been developed yet.“Walki Evo Seal” has a dispersion coating acting as a barrier against water vapor and grease.

“High barrier paper is possible, but we’re all on the journey; it’s not plug and play and certainly not as easy as people think. There is complexity around technologies, raw materials, components, and the way it is processed. It’s coming, but for high barrier applications today, I would suggest plastics, specifically PE with a barrier (EVOH or coatings).”

“The issue everyone faces is that paper is more expensive than plastic and can require major shelf life tests before launch and packing machine cost adjustments. One must commit to a paper future knowing the current cost structure will change.”

Tax considerations
Much of Walki’s packaging sold in the UK is predominantly fiber-based by weight and therefore exempt from the UK Plastic Packaging Tax. The company also offers 50% and 70% TUV-accredited PCR films for non-food applications, which also meet the tax’s 30% recycled content mandate.

“PCR content has been difficult to access, but having the collection system for PCR locally in Spain, where our factory is based, has certainly helped, allowing us to sidestep scarce recycled material volumes,” adds Jones.

Reports have surfaced that the high demand and low availability of recycled plastic have made paying the tax more cost-effective than incorporating PCR, especially for food-grade applications. The situation is made worse by the UK’s disjointed collection systems and the government’s refusal to guarantee that funds generated through the tax will be put toward improving recycling infrastructure.

By Joshua Poole