Paper vs. plastic: BillerudKorsnäs FibreForm trays slash climate impact by 70 percent

01 Oct 2019 --- Packaging trays made from BillerudKorsnäs’ FibreForm paper have up to 71 percent less global warming impact compared to trays made of only plastic. This is according to a life cycle assessment (LCA) performed by the Research Institutes of Sweden (RISE). The main reason for the lower global warming potential is that the FibreForm laminate requires less energy in production than plastic. Also, the tray can be recycled as paper in most European countries, which reduces the end-of-life impact.

The first tray made of FibreForm was released to the market about 10 years ago and has been further improved together with production partners. FibreForm has since been used to create several innovative packaging solutions, including the U-Bend straw in collaboration with The Paper Straw Co and the Pearl packaging concept in collaboration with Bosch Packaging Technology.

The LCA of FibreForm trays is the first of its kind to compare the environmental profile of plastic-based trays against paper. The difference in climate impact is substantial, says Michael Sturges, who led the study at RISE.

The study compares FibreForm trays with conventional EPS trays and APET/PE laminated plastic trays. The study encompasses all stages of the product life cycle, from raw material production to landfill or recycling. At 20 kg CO2e per 1,000 trays consumed and disposed of, the FibreForm tray offers a 62 percent reduction in global warming potential compared to the EPS tray and a 71 percent saving compared to the APET/PE tray. The work has been peer-reviewed by Intertek, a global leader in the field of verification and assurance.

“We developed FibreForm to challenge conventional packaging to reduce unnecessary plastic packaging. The 3D-formable material makes it strong and stable. We believe that we create sustainable growth by offering alternative packaging possibilities together with our partners,” comments Hein van den Reek, Business Director Solutions at BillerudKorsnäs.

The FibreForm tray is approved for food contact and can be found in retail stores as packaging for cheese, meat, fish and other similar foods. The material can be formed in existing thermoforming lines and press-forming equipment on the market, meaning that food processors, brand owners and retailers can make an easy switch in their production.

Bend me, shake me
In July, BillerudKorsnäs announced its intention to launch a functional 180 degree bendable straw made out of FiberForm later this year for food and beverage industries in the UK and US. The Paper Straw Co will produce the patent-pending U-Bend straw in Manchester, UK, and the US for individual drink cartons such as juice, milk and water.BillerudKorsnäs' 180 degree bendable straw (U-Bend).

Speaking at the recent FachPack 2019 show in Nuremberg, Thomas Fettkenheuer, Sales Manager Formable Solutions for BillerudKorsnäs, tells PackagingInsights that “the project is still in the development stage but the durability of the straw in drinks is already long-lasting.”

Fettkenheuer notes that the supplier is already receiving increased demand for its fiber-based solutions as a result of the Council of the EU’s official adoption of measures proposed by the European Commission to tackle marine litter by banning the 10 single-use products most commonly found on European beaches. This includes single-use plastic straws. The EU Member States have less than two years to transpose the legislation into their national law.

A real pearler
The packaging concept Pearl aims to show how uniquely formed and ideally sized small packages can contribute to a more sustainable future. They utilize the formability of the FibreForm material and are processed on machinery from Bosch Packaging Technology.The Pearl packaging concept utilizes the formability of FibreForm from BillerudKorsnäs and the machinery capabilities of Bosch Packaging Technology.

Speaking at FachPack 2019, Torsten Sauer, Project Director Sustainable Packaging Solution for Bosch Packaging Technology, tells PackagingInsights that, “Using FiberForm we can create a very innovative type of packaging to replace single-use packaging. We need a special type of paper to stretch paper into three-dimensional shape and that is what BillerudKorsnäs provides with its long fibers and modified stretchability.”

“As the machine supplier, we have experience in forming, filling and sealing. We can convert BillerudKorsnäs’ paper into sustainable and attractive consumer packaging.”

Pearl packaging can be used across “unlimited” food and non-food applications, including biscuits, chocolates, hardware and cosmetics, says Sauer.

By Joshua Poole