Join us at the 2024 Virtual Solutions Summit on June 4-5 for innovative insights and networking opportunities.
Packaging has undergone a remarkable transformation since its origins. Initially, during the late 1800s, packaging was a luxury, used primarily for expensive goods and designed to be reused rather than disposed of. As industrialization progressed, however, the advent of cheaper, mass-produced packaging in the early 20th century led to an era of convenience-driven, disposable solutions that significantly increased packaging waste globally. The shift from durable to disposable was driven by marketing and consumer convenience but came at a high environmental cost.
Change is underway once again, though it is progressing slowly at a time when urgency demands a much faster pace. From the first paper cardboard box invented in 1817 to today’s advanced, eco-friendly materials and technologies, the focus is shifting towards reducing environmental impact and embracing circular economy principles.
The global packaging landscape presents daunting figures: annually, around 300 million tons of plastic waste are produced, with the vast majority originating from packaging. Despite the high recyclability of materials like corrugated boxes—over 80 billion are used yearly—less than 20% of all plastic is recycled worldwide.
E-commerce has significantly increased the demand for packaging, adding to the environmental burden and underscoring the urgency for enhanced sustainable practices, further propelled by growing consumer demand and more stringent regulatory pressures. The movement towards sustainability is shaping innovative trends in the packaging industry, aiming to minimize environmental impacts and transform packaging into a more sustainable entity.
Having covered numerous packaging innovations over recent years, National Packaging Design Day provides a great time to reflect on and share the top 10 sustainable trends shaping the industry in 2024 and beyond.
Seaweed emerges as a stellar material in food-based sustainable packaging due to its biodegradable and edible properties. Innovators like Notpla and Evoware are leading the way by creating packaging solutions that vanish naturally - by composting or even just dissolving in warm water. Seaweed grows abundantly in marine environments and does not require fertilizers, fresh water, or land for cultivation, making it a low-impact resource. Its cultivation can also help absorb carbon dioxide, mitigating the effects of climate change.
Turning industrial byproducts into valuable packaging materials is a growing trend, and companies are creatively using remnants from agriculture, textiles, and other industries to manufacture new products, thereby reducing landfill waste. Upcycling presents a significant opportunity to contribute to a circular economy by reducing waste, saving natural resources, and creating economic value from otherwise discarded materials. Companies and startups focusing on upcycling are increasingly recognized for their positive environmental impact and are finding additional support through various green initiatives and policies.
Small-footprint reusable pallets and containers are revolutionizing the logistics sector by enhancing operational efficiency and reducing waste. Reusable transport packaging (RTP) is a multi-trip packaging medium that can transport products and goods more than once. RTPs typically consist of durable containers like pallets, trays, totes, and racks made from solid materials like wood, metal, and plastic. Reusable packaging’s capacity to be used many times offers significant benefits in terms of sustainability, cost savings, and productivity. The push for reusable packaging systems is transforming logistics and food service sectors, with companies such as Tosca and Returnity at the forefront, offering solutions that significantly lower the environmental impact of packaging by extending its lifecycle through repeated use and recycling. Beyond RTP's, there are many other industries that will benefit greatly from continued exploration of how to better embrace reusability over single-use solutions, such as the beverage industry.
Mono-material packaging refers to solutions made from a single material type, significantly simplifying recycling processes. This approach contrasts with traditional packaging that often combines different materials, such as plastics, metals, and fibers, which can complicate recycling efforts due to the need for separation and specialized processing. Mono-material packaging is fully recyclable, consisting of only one material type, making it easier to process in standard recycling facilities without separating. By improving the efficiency of the recycling process, mono-material packaging reduces waste and resource consumption, minimizing the environmental impact of both production and disposal.
Bioplastics, derived from natural materials like corn starch, are gaining traction as a compostable alternative to conventional plastics, breaking down into natural substances like carbon dioxide, water, and biomass under specific conditions. While compostable plastics offer an eco-friendly alternative to traditional plastics, their environmental impact depends on proper disposal and composting, often in industrial composting facilities. Inadequate composting and potential consumer confusion about disposal can limit their benefits. Research is ongoing to develop new compostable plastics with enhanced properties and reduced dependence on industrial facilities. There is a growing emphasis on home-compostable plastics and the development of materials that can degrade in a broader range of environmental conditions.
Digital printing technology enhances packaging customization and reduces waste by eliminating the need for plates and reducing setup materials. This allows for rapid, on-demand printing that minimizes overproduction and material usage, making it a key player in sustainable packaging practices. Advancements in ink formulations, such as UV-curable and water-based inks, have also significantly reduced the environmental impact. Eco-friendly packaging that uses sustainable materials and practices can benefit from digital printing to maintain environmental standards throughout production.
Smart packaging encompasses a range of technologies designed to extend the functionality of traditional packaging through enhanced communication, safety, and quality features. These solutions can be broadly categorized into two types: active packaging, which improves the condition of the packaged products, and intelligent packaging, which provides information about the status of the products. Smart packaging improves product tracking, user interaction, and lifecycle management by incorporating technologies such as IoT and RFID. It is critical in enhancing packaging functionality, from extending product freshness to providing vital consumer information. Developing smart packaging solutions that are intelligent and sustainable is crucial, as well as combining intelligence with other aspects that focus on using biodegradable or recyclable materials to reduce environmental impact.
Packaging embedded with seeds that can be planted after use embodies an innovative approach to waste reduction. This type of packaging, often made from recycled or natural materials, turns waste into green growth, adding a new dimension to the environmental benefits of sustainable packaging practices. The success of the seeds can be highly variable, however, depending on the environmental conditions where the packaging is planted. There can also be restrictions on the transportation of seeds between different regions or countries to prevent the spread of non-native plant species. As consumer demand for sustainable packaging solutions increases, the popularity of plantable packaging is likely to grow. Materials science and biotechnology innovations could lead to broader applications and more cost-effective production methods. Educating consumers on properly using and disposing of plantable packaging will be vital to maximizing its environmental benefits.
Concentrated product formats and refill systems reduce the need for extensive packaging, cutting down on waste and emissions associated with transportation, with a trend that conserves resources and encourages consumer participation in sustainability. The rise of zero-waste stores and the expansion of refill options in mainstream supermarkets are signs of gaining momentum. Innovation continues in formulating and improving packaging, with developments in biodegradable and even edible packaging materials. Technology also plays a role, with some companies experimenting with innovative refill systems that alert consumers when it’s time to reorder or provide precise dilution mechanisms to ensure product efficacy. As technology and consumer acceptance evolve, these systems are likely to become more widespread and effective, significantly reducing the environmental footprint of everyday products.
Technologies enabling on-demand packaging production ensure that materials are only used as needed, reducing excess and aligning with just-in-time manufacturing principles. This approach is particularly advantageous for e-commerce, where custom packaging solutions can be generated instantly to fit diverse product dimensions and reduce waste. The cost of setting up an on-demand packaging system can be high due to the need for advanced digital printing equipment and automated machinery, and while on-demand packaging is highly efficient, scaling up production to meet large spikes in demand can be challenging without compromising the speed or quality of output. With continuous technological advancements, the growth outlook should see on-demand packaging becoming standard practice, particularly in industries that value customization and sustainability.
While each packaging trend faces challenges, from economic viability to consumer acceptance, the opportunities they present in fostering a sustainable future are immense. As technology advances and market acceptance grows, these sustainable packaging innovations will become more prevalent, driving industries toward an eco-friendlier future.
Join us at the 2024 Virtual Solutions Summit on June 4-5 for innovative insights and networking opportunities.
