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Paper-based packaging gaining popularity as solution to waste reduction

With efforts being made to offer alternatives to plastic-based packaging, the food industry has renewed efforts to introduce paper- and even plant-based options to complement the sustainably produced food products they serve to protect.

It’s not just food: Pernod Ricard-owned Absolut Vodka is selling its paper bottle in UK supermarket chain Tesco as part of a three-month pilot test – although the pilot has been subject to accusations of greenwashing.

Fellow UK supermarket Sainsbury’s has this month replaced the plastic packaging on its “by Sainsbury’s” steak range, removing 70% of plastic per tray. The new packaging, which was launched across 10 products, is hoped to save 249 tonnes of plastic per year.

Sainsbury’s Plan for Better commitment aims to reduce plastic use

“As part of our Plan for Better commitments, we are trying to reduce plastic packaging across our own-brand ranges,” said Claire Hughes, director of product and innovation at Sainsbury’s.

“It’s why we are always looking at ways to innovate our packaging and reduce or replace plastic wherever we can, as quickly as we can. We know there is more to do and we are committed to making bold changes that help us achieve our plastic reduction targets.”

The shift to paper is not only because of its green credentials as a renewable material. Its versatility as food packaging means it is suitable as protection for bread, wrap for chocolates, and containers for ready meals and pizzas.

Corporations like Kraft Heinz and Carlsberg are investing millions to produce paper packaging that can do the jobs plastic does to hopefully leave a lighter footprint on the planet. Nestlé, for example, is using paper for its KitKat and Quality Street packaging.

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PepsiCo trials nanotechnology to cut down on carbon emissions

Another example is PepsiCo, which in March began testing paper-based, recyclable outer packaging on its Walkers Baked six-bag multipacks, following a successful trial with Walkers 22- and 24-bag multipacks last year.

The packaging is a first for savoury snacks, with nanotechnology employed to introduce air bubbles into the film to reduce the amount of plastic used, while retaining the strength and stretch needed.

PepsiCo claims the packaging will result in a 40% reduction in virgin plastic year-on-year compared with the previous film, meaning the conglomerate will reduce its annual carbon emissions by 465 tonnes.

“After more than two years in development, we’re looking forward to testing this paper-based outer material with our consumers to better assess the role it could play in our future packaging portfolio,”said Gareth Callan, packaging sustainability lead at PepsiCo UK & Ireland.

Rachel Smith, senior marketing manager for Walkers, added: “With this latest trial, people can buy a selection of Walkers Baked multipacks in paper-based outer packaging that can be easily and widely recycled with regular recycling at home.”

Plastic-based packaging becomes recyclable with ‘holistic solution’

With all the attention on paper, is there still a role for plastics in packaging? The main problem with this material is its multi-structure composition, where petroleum-based ethylene vinyl alcohol copolymer (EVOH) and met-PET (metallised polyester film) plastics often feature in packaging lids.

EVOH, which is normally included on the thin plastic films of food packaging to serve as an oxygen barrier, is non-recyclable, preventing the entire package from being recyclable.

But Israeli packaging solutions developer Melodea believes it has created a solution to the problem with its new water-based, plant-sourced barrier coating that allows the packaging to be recycled.

Called MelOx NGen, the coating, which was released earlier this month, is designed to line the inside surfaces of plastic food packaging without the use of primers, making it suitable for protecting and extending the shelf-life of snacks, confectionery, nutrition bars, meat, and dairy products.

“The global collective effort to drastically curb plastic use is a long and complex process,” said Shaul Lapidot, CEO and co-founder of Melodea.

“Our holistic solution can help ease the pressure by boosting the integration of plastic packaging into the circular economy, immediately.”

MelOx NGen has been approved as safe for contact with food by the US Food and Drug Administration and the Federal Institute for Risk Assessment in Germany.