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Rethinking Packaging: A Shift Toward Sustainability

Sustainable packaging is the need of the hour, given the environmental damage caused by conventional packaging materials, says Milton D’Silva.

Rethinking Packaging: A Shift Toward Sustainability

Wikipedia describes packaging as the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging may also be described as the process of designing, manufacturing and using containers of various types for protection and safe transportation products, from the point of origin to the end users. As products are widely produced and traded, the market for packaging is huge, valued at approximately US$1.24 trillion in 2024 and projected to reach around US$1.69 trillion by 2034, expanding at a Compound Annual Growth Rate (CAGR) of 3.16%.

Today, about 40% of the packaging materials used globally are plastics, thanks to its many advantages like flexibility, durability, and lightweight nature. Estimates also suggest that roughly a quarter of all plastics produced globally are used in packaging. Plastic, as is commonly acknowledged, is not easy-to-recycle material and over 80% of it ends in landfills, creating a huge problem for the environment. This in turn has led to the need for sustainable packaging.

So what exactly is sustainable packaging, and why is it important? Sustainable packaging may be described as packaging that makes use of reusable or recyclable materials that minimise environmental impact without compromising on the ideal requirements of packaging. Sustainable packaging means reducing the use of materials and resources, also minimising energy requirements in the process.

Globally, more and more consumers are now aware of the perils of plastic packaging materials and the harm they are causing to the environment. Findings of some recent surveys on the harmful effects of plastic packaging materials on the environment have some interesting results. Over 80% of the consumers in the developed world have expressed concerns about it. This has in turn led to a demand for sustainable packaging that can minimise the environmental impact through the use of recyclable, reusable, and compostable materials, thereby reducing waste, as well as energy consumption, during production and transportation.


Rethinking Packaging: A Shift Toward Sustainability
Plastic waste is polluting water bodies, rivers and the oceans. Photo by Fayegh (Shamal) Shakibayi on Usplash

This article examines at length the issues associated with packaging and packaging materials, the problems caused by their rampant use in a booming consumer market, and the demand for sustainable packaging materials.

The need for sustainable packaging
Today, the environmental impact of traditional packaging materials – whether fossil fuel-based products like plastics, or plant-based materials like paper and cardboard – is all too obvious. Rampant use of these materials is leading to significant harm to the environment through pollution on the one hand, and depletion of natural resources on the other. It is also leading directly to increased greenhouse gas emissions, and serious landfill issues, causing soil and water contamination, in the process also polluting water bodies, rivers and the oceans.

The worst offender when it comes to packaging materials is plastic. As a synthetic polymer made from chemicals derived from petroleum, plastic is not a biodegradable material in nature. This means plastic cannot be broken down by natural processes, like bacteria and fungi, into simpler substances like carbon dioxide, water, and biomass. The result is a burgeoning global crisis that is causing severe environmental damage, harming wildlife, disrupting ecosystems, and posing risks to human health through toxic chemicals and microplastics.

The carbon footprint caused by packaging materials is substantial as it encompasses all greenhouse gas emissions throughout their lifecycle, from raw material extraction to final disposal. Traditional packaging materials like plastic and non-recycled paper have a higher impact due to energy-intensive production and disposal processes. According to the United Nations Environment Programme (UNEP), every day the equivalent of 2,000 garbage trucks full of plastic are simply dumped into the world's oceans, rivers, and lakes. Every year 19-23 million tonnes of plastic waste leaks into aquatic ecosystems, polluting lakes, rivers and seas. Plastic pollution can alter habitats and natural processes, reducing the ecosystems’ ability to adapt to climate change, directly affecting millions of people’s livelihoods, food production capabilities and social well-being.


Rethinking Packaging: A Shift Toward Sustainability
Dumping ground littered with single-use plastics. Image by Pete Linforth from Pixabay

Challenges in waste management and recycling
The challenges in managing plastic waste, or recycling it, are many. These include inadequate infrastructure, lack of public awareness, financial constraints, and inefficient collection and disposal systems, which impact the environment and public health. Most residential areas, especially in developing countries, do not have effective waste collection, sorting and processing facilities. This results in overflowing bins, haphazard collection without any segregation of waste and dumping it at landfill sites or some makeshift dumping ground. While it is possible to recycle most plastic waste, in the absence of proper business models and investments, there are no mass-scale recycling facilities. Countries like Singapore, Japan and Sweden have a very high rate of waste recycling, including plastic waste. But these are exceptions rather than the norm.

Apart from outdated garbage collection and disposal infrastructure, leading to slow operations and increased costs, the other significant challenge is a lack of public awareness and participation. Most people simply do not understand the importance of reducing waste generation, nor do they care to segregate their waste while disposing it off. This in turn, hinders the municipal efforts of effective waste management. As the cost of waste collection, transportation, and disposal can be high, especially in thickly populated urban areas, over a period of time the operations become highly inefficient and inadequate, suffering from financial constraints.

Global regulations on packaging waste
Concerned over the relentless growth of packaging requirements and ballooning waste generation, most countries are getting into the act of controlling this menace. Globally, regulations on packaging waste are still evolving, but the contours that are emerging have a strong focus on reducing waste, promoting reuse and recycling, and limiting the environmental impact of packaging, particularly plastic.

Key trends and regulations can be summarised as:
  • Bans and restrictions on single-use plastics: Many countries and regions are implementing bans or restrictions on single-use plastics, such as bags, straws, and certain types of packaging, to reduce waste and pollution.
  • Extended Producer Responsibility: EPR schemes hold manufacturers responsible for the end-of-life management of their packaging, incentivising them to design for recyclability and reuse.
  • Recycled content targets: Regulations often set targets for the percentage of recycled content in packaging, encouraging the use of recycled materials and reducing reliance on virgin materials.
  • Design for recyclability: Packaging is increasingly required to be designed for recyclability, ensuring that materials can be easily separated and processed for recycling.
  • Minimising packaging: Regulations aim to reduce the amount of packaging used, focusing on minimising unnecessary packaging and promoting efficient packaging solutions.
  • Reusable packaging: There's a growing emphasis on promoting reusable packaging systems, such as deposit return schemes and encouraging the use of reusable containers for take-away food and beverages.
Besides these general trends, there are many country- and region-specific initiatives like the EU Packaging and Packaging Waste Regulation (PPWR), US Plastic Waste Reduction Act, Denmark's PFAS Ban, and India's Plastic Waste Management Rules – 2016, among other remedial measures.

Types of sustainable packaging
There is no dearth of sustainable packaging materials today. Even traditional packaging materials that are plant based, like paper and cardboard, are sustainable if these are sourced from responsible forestry practices. In practice, however, rampant use of plant based materials leads to deforestation, and hence, is harmful to the environment. Recycled paper products are certainly sustainable, and the emphasis today is on recycling most paper products used in packaging rather than sending it to landfills. There are many other options when it comes to sustainable packaging materials besides paper products, as summarised below.

1. Biodegradable and compostable materials
  • PLA (Polylactic Acid) – A bioplastic derived from renewable resources like cornstarch or sugarcane, offering a biodegradable alternative to traditional plastics.
  • Cellulose – Derived from natural sources like wood pulp and cotton, cellulose is a biodegradable and compostable material with moisture-resistant properties, making it suitable for food packaging.
  • Mycelium Packaging – Packaging made from the root structure of fungi (mycelium) offers a sustainable alternative to traditional packaging materials.
  • Cornstarch-based Foam – A biodegradable and compostable foam packaging alternative to traditional polystyrene.
  • Edible Packaging – Packaging made from edible materials like seaweed or plant-based films, offering a completely waste-free solution.
  • Sugarcane Pulp – A renewable and biodegradable material that can be used for packaging.
2. Recyclable materials
  • Cardboard and Corrugated Paper – Highly recyclable and versatile materials for packaging, offering good strength and cushioning.
  • Recycled Paper and Card – Using recycled paper and card reduces the need for virgin materials and minimises waste.
  • Recycled Plastic – Using recycled plastic in packaging reduces the environmental impact compared to virgin plastic, requiring less energy to manufacture and reducing greenhouse gas emissions.
  • Glass – A natural and sustainable material that is widely used to store products like moisturisers and serums due to its high recyclability.
3. Other sustainable materials
  • Kraft Paper – A strong and durable paper material that is widely used in packaging, offering a sustainable alternative to plastic.
  • Jute – A natural fibre that is used to make bags and other packaging materials, offering a sustainable alternative to synthetic materials.
  • Wool – A natural, renewable, and biodegradable material that can be used for packaging.

Rethinking Packaging: A Shift Toward Sustainability
Wooden pallets are used extensively. Image by Freepik

Biodegradable and compostable packaging
The various categories of materials classified as biodegradable and/or compostable are not always what they seem. To be considered biodegradable, the material must decompose by the action of living organisms such as microbes (bacteria, fungi), into water, carbon dioxide, and biomass. For packaging materials to be considered truly biodegradable, they should ideally break down within a year or less, ideally within months, under composting conditions, transforming into water, carbon dioxide, and biomass through the action of microorganisms. Otherwise, all materials are inherently biodegradable, whether it takes a few weeks or a million years to break down into organic matter and mineralise. To that extent, there is a lot of misrepresentation and greenwashing by companies to present their products as more environment-friendly than they actually are. The most widely used petroleum-based plastics such as polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), and polystyrene (PS) are not biodegradable. Yet there are a few petroleum-based plastics that are considered biodegradable. These include: Polyglycolic acid (PGA), Polybutylene succinate (PBS), Polycaprolactone (PCL), Poly(vinyl alcohol – PVA, PVOH), and Polybutylene adipate terephthalate (PBAT).

Similar is the case with compostable materials. While compostable plastics biodegrade, they are specifically designed to be processed in composting facilities, which provide the necessary conditions (temperature, moisture) for decomposition. Without these industrial composting facilities, the materials do not really break down into their natural constituents and stay in the environment as harmful particles or microplastics, which today have been found in human bloodstream.

Minimalist and zero-waste packaging
One practical solution that is gaining popularity when it comes to sustainable packaging is the minimalist approach – using the least amount of materials with innovative design elements. The supermarkets are full of farm produce stacked on endless shelves wrapped in layers of plastic and then placed in styrofoam containers. Minimalist packaging focuses on simplicity and efficiency, using only what's necessary to protect the product and convey essential information. It eliminates unnecessary layers, fillers, and decorative elements to minimise waste by considering only the protection and functionality of the packaging, rather than flashy aesthetics. Minimalist packaging also promotes only recyclable or compostable materials like kraft paper, cardboard, or biodegradable plastics.

The other alternative, zero-waste packaging, is even more radical – simply minimise or altogether eliminate waste by using reusable, recyclable or compostable materials. Gas cylinders – domestic and industrial – are fine examples of reusable packaging, also used for water in large containers in many places. Above all, zero-waste packaging is focused on totally eliminating the use of single-use plastics that contribute most to environmental pollution. By promoting responsible use of resources, this helps reduce waste and protect ecosystems.

Innovations in sustainable packaging
Innovations in sustainable packaging today focus on advanced materials and coatings like biodegradable and compostable polymers, mycelium-based packaging, and edible coatings, alongside smart packaging with sensors and data carriers, all aiming at reduced environmental impact and increased functionality.

A range of advanced materials like PLA (polylactic acid), PHA (polyhydroxyalkanoates), and thermoplastic starch offer alternatives to traditional plastics, breaking down naturally in compost or industrial settings. Mycelium-based packaging that uses the root-like structure of fungi (mycelium) to create biodegradable and sustainable packaging, offers a natural and renewable alternative to polystyrene. Then there are Cellulose Nanocrystals, which are derived from agricultural waste. These nanocrystals offer lightweight, strong, and renewable packaging alternatives. There are also bioplastics – plastics made from renewable resources like corn, sugarcane, and potatoes, which can biodegrade in the environment.


Rethinking Packaging: A Shift Toward Sustainability
Ecommerce companies are leading the drive for sustainable packaging. Image source: Amazon Shipping

When it comes to coatings, there are various options one can choose from:
  • Edible Coatings: Coatings made from natural polymers that can be eaten along with the product, reducing the need for traditional plastic packaging.
  • Water-Soluble Films: Films that dissolve in water, offering a sustainable alternative to traditional plastics.
  • Biodegradable Coatings: Coatings that provide water resistance, gloss, and durability to packaging materials while also being biodegradable.
Smart packaging, earlier restricted to very expensive and sensitive consignments, is another emerging trend that has now entered the packaging arena. Thanks to innovative technologies and benefits of economies of scale, smart packaging integrates technology into packaging to improve sustainability, such as smart labels, NFC chips, RFID, and QR codes, for product authentication and connection. This is supplemented or augmented by active packaging – packaging that includes active components to enhance food preservation and quality, such as sensors to monitor freshness or biosensors to detect spoilage. Besides, there is nanotechnology applied in coatings to formulate edible coatings and improve their performance, safety, and storage.

Towards circular economy
Unlike traditional economies where resources are harvested or mined, made into products, and then become waste, the Circular Economy envisages elimination of waste by keeping products in circulation for as long as possible. This is achieved by a combination of superior design of materials, products, and systems at the manufacturing stage, and maximising reuse and recycling over the life cycle. Like the minimalist approach, the circular economy model also aims at transforming packaging by reducing waste and promoting reuse. However, the user industry must also take the lead by sourcing sustainable materials, recycled products or bio-based options to take this forward.

How exactly would these practices improve packaging efficiency, reduce environmental impact, and support long-term sustainability goals? By challenging the traditional linear approach of ‘use and discard’ in favour of a sustainable strategy focused on ‘reduce, reuse and recycle’.

Key principles of a circular economy for packaging:
  • Reduce: Minimise the amount of packaging used by designing lighter, more efficient packaging or eliminating unnecessary packaging altogether.
  • Reuse: Design packaging for multiple uses, such as reusable containers or bottles, or explore refill and return programs.
  • Recycle: Ensure packaging is designed for recyclability, using materials that are readily recyclable and supporting robust recycling infrastructure.
Packaging-as-a-service
A notable sustainable packaging trend making a comeback is Packaging-as-a-Service (PaaS), where the focus is on reusable and refillable packaging systems. Under the PaaS model, vendors provide reusable and returnable packaging solutions to businesses. This is not exactly a new trend as much before the popularity of cheap plastic packaging took over, an early model of reusable packaging existed, especially for milk in glass bottles, which was in a way the forerunner of the PaaS model. In the basic PaaS model, businesses rent or lease packaging instead of buying it, which can significantly boost sustainability by reducing waste, promoting circularity, and optimising resource use, offering a more eco-friendly alternative to traditional packaging practices.

How exactly does the PaaS model work in practice? Since this is basically a Subscription or Rental model, companies subscribe to a service that provides them with packaging for their products. The packaging is designed to be durable and reusable, often for multiple trips. The service provider collects the used packaging from customers and cleans and redistributes it. In essence, the PaaS models minimise waste by eliminating the need for single-use packaging and promoting a circular economy. By reusing packaging, companies can reduce their reliance on raw materials and energy consumption associated with packaging production.

AI and other technologies in sustainable packaging
AI and emerging technologies can significantly boost sustainable packaging by optimising material usage, streamlining processes, enabling smart packaging, and improving recycling efficiency, ultimately leading to reduced waste and environmental impact. AI-driven systems can precisely measure and cut packaging materials, ensuring minimal excess and maximum use. AI-powered analytics can analyse vast amounts of supply chain data, identifying areas for reducing packaging waste and improving efficiency. AI algorithms can optimise packaging layouts, enhancing material efficiency and minimising excess packaging.

AI-powered systems can track products in real-time, improving safety and reducing loss. For example, AI-powered vision systems can detect defects or irregularities in packaging materials, ensuring high-quality packaging and reducing waste. Apart from AI, robotics and intelligent machines can streamline packaging processes, reducing material wastage and boosting overall efficiency. Smart packaging solutions can also incorporate sensors and data analytics to monitor and control factors like freshness, temperature, and shelf life, ensuring optimal product condition.

Challenges and barriers to adoption
Widespread adoption of sustainable packaging solutions faces numerous challenges. As happens with many problems that are waiting for effective solutions, cost ranks as the numero uno challenge as sustainable packaging materials and processes often come with a higher upfront cost compared to conventional options. Consumers used to cheap plastics are loath to pay more even with growing awareness, and manufacturers invariably push this additional cost in the cause of sustainability to the consumers. An effective via media has to be found with suitable regulatory mechanisms.

The next significant barrier is infrastructure limitations, as finding and securing sustainable materials can be challenging, leading to supply chain disruptions apart from increased costs. The (as yet) smaller demand for sustainable packaging compared to conventional packaging means lower production volumes, which can lead to higher per-unit costs. Moreover, not all products can be packaged in sustainable materials, and the availability of certain sustainable materials can be limited. A more serious issue is not all sustainable packaging materials offer the same level of protection or shelf life as conventional materials.

The third challenge pertains to regulatory mechanisms and uncertain or unclear policies. Different regions and countries have different regulations and standards for sustainable packaging, making it difficult for businesses to comply with all requirements. Also there is often a lack of clear policy guidelines and standards for sustainable packaging, making it difficult for businesses to know what is considered sustainable.

Finally, there is skepticism on part of the consumers, especially regarding the claims made about the sustainability of certain packaging materials or processes. Many consumers may also not be aware of the environmental impact of their packaging choices or the benefits of sustainable packaging. Consumers used to fancy packaging with multiple layers may well be reluctant to switch to sustainable packaging if it is inconvenient or if they perceive it as being of lower quality.


Rethinking Packaging: A Shift Toward Sustainability
The quest for alternative packaging materials. Photo by Boxed Water Is Better on Unsplash

Future trends and opportunities
As mentioned earlier, today climate change and the need to rein in rising temperatures leading to global warming have sensitised consumers to the perils of damage caused to the environment. As a result, the demand for sustainable packaging has gathered momentum. Sustainability has now become an important factor influencing purchase decisions across the world. This trend has received a boost with the rise of ecommerce companies, who are now leading the drive for sustainability in packaging. Not only are these companies adopting eco-friendly materials and optimising packaging sizes, they are also using innovative technologies like QR codes for recycling information, and at the same time reducing waste and emissions.

In the contemporary scenario, the emerging trends in sustainable packaging include innovative materials like biodegradable plastics and seaweed-based packaging, reusable systems, minimal designs, and smart packaging solutions. Together, these offer opportunities for businesses to reduce environmental impact and meet consumer demand for eco-friendly products. Prominent among innovative materials are biodegradable and compostable materials, signalling a shift away from traditional plastics. These include alternative materials like plant-based plastics (PLA), mushroom packaging, and seaweed-based packaging. This is complemented by increasing use of recycled products to reduce reliance on virgin materials and promote a circular economy. Two other emerging trends are mono-materials, which simplifies packaging design by using single materials instead of laminates and composites to improve recyclability; and edible packaging, a recent and revolutionary solution, which offers a sustainable and consumer-friendly approach to food packaging. Other trends like reusable packaging systems such as returnable containers and refillable packaging, and refillable packaging options also promote sustainable consumption patterns.

Summing up
The drive for sustainable packaging is unfolding through increasing consumer demand, stricter regulations, and companies adopting innovative, eco-friendly solutions, with a focus on reducing waste and promoting circularity. According to a recent research report published by Towards Packaging, a global consulting firm, the sustainable packaging industry is set to grow from US$294.30 billion in 2024 to US$557.65 billion by 2034, at a 6.6% CAGR. Going forward, the objectives of sustainable packaging can be achieved by a combination of growing environmental consciousness and the willingness of consumers to pay a little more for their purchases on account of eco-friendly products and packaging. This will have to be complemented by the willingness of companies to prioritise sustainability with a commitment to the environment, and above all, appropriate policy initiatives backed by legislation aimed at reducing packaging waste, particularly single-use plastics, and promoting the use of recycled and biodegradable materials.

References
1. https://www.statista.com/statistics/1535934/global-market-value-of-packaging/
2. https://tipa-corp.com/faq/
3. https://en.wikipedia.org/wiki/Biodegradable_plastic
4. https://www.towardspackaging.com/insights/sustainable-packaging-market-sizing

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