VerticalBlueLine Flexible Packaging

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Compostable Packaging

What are the challenges faced by companies in adopting compostable packaging solutions?

Companies face several key challenges in adopting compostable packaging solutions. A major hurdle is cost, as compostable materials tend to be more expensive than traditional plastics. However, there is rising consumer demand for sustainable packaging, with 71% of European and 70% of US consumers wanting to buy sustainable products.

Another obstacle is consumer confusion about composting. Consumers struggle to identify compostable packaging, with 49% confusing terms like “biodegradable” and “compostable.” Standardized labeling and education campaigns are needed to resolve this confusion and contamination of waste streams.

Design also plays a role. Certain colors and shapes mislead consumers on compostability. Companies should design packaging to clearly communicate proper disposal.

Finally, there is a lack of infrastructure, as companies need better systems for collection and commercial composting. Building this infrastructure requires collective action from brands, policymakers and composters.

While challenges remain, consumer demand and environmental benefits present a compelling case for compostable packaging. With a tailored approach considering costs, infrastructure, design, and education, companies can overcome hurdles to adoption.

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Compostable Packaging

Consumer Behavior

Consumer Behavior

What are the consumer preferences when it comes to sustainable packaging design?

Consumers are increasingly concerned about sustainability and want companies to adopt more environmentally friendly packaging. According to the ESW survey, nearly 60% of Gen Z and millennial shoppers decline to purchase from brands seen as unsustainable. A Bain report notes 71% of European consumers want sustainable products, and McKinsey finds that younger consumers prioritize environmental impact more.

While consumers care about sustainability, other factors such as price, quality, hygiene, and food safety remain top priorities, according to surveys by McKinsey and Bain. Bain's study also reveals that 70% of consumers incorrectly believe single-use glass has lower carbon footprint than single-use plastic, indicating consumer confusion on packaging sustainability.

Consumers want clear recycling instructions, and 84% of Europeans are seeking them, according to Amcor. They also respond well to sustainability logos, which positively influence 60% of European purchase decisions. FSC and PEFC certification matter too, according to Two Sides.

Regarding materials, consumers perceive plant-based and compostable packaging as very sustainable but lack consensus on others, McKinsey reports. Paper scores well for sustainability in some countries like the UK. Plastic films from renewable/compostable materials are gaining favor, McKinsey notes.

In summary, consumers increasingly want sustainability but remain confused on packaging materials. Providing clear recycling instructions, sustainability logos, eco-friendly materials like paper, and FSC/PEFC certification can appeal to consumers’ sustainability preferences. But quality, price and hygiene must not be sacrificed.

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Biobased Materials

What are the pros and cons of using biopolymers in flexible packaging?

  • Pros:
    • Biopolymers from natural sources like avocado peels, bacterial cellulose, and starch can be used to create biodegradable and compostable packaging films that reduce plastic waste and microplastic pollution.
    • Essential oil-infused biopolymer films have enhanced antibacterial and antioxidant properties, allowing for active packaging that can help preserve foods.
    • Some biopolymer films like the cellulose-soy composite have high tensile strength, transparency, and water resistance akin to plastic, while still being biodegradable.
    • Biopolymer films often have better oxygen barrier properties compared to plastic, helping to maintain food freshness.
  • Cons:
    • Biopolymer films may be more expensive than conventional plastic films.
    • Some additives used in biopolymer processing could potentially leach out and be toxic, requiring more safety testing.
    • Biopolymer films can have inferior moisture barrier properties compared to plastic, requiring additional modifications.
    • Limited large-scale infrastructure and lack of consumer education are barriers to biopolymer adoption.
    • Biodegradable films may still pose risks to wildlife if littered and ingested before degrading.

In summary, biopolymers show promise as more sustainable flexible packaging materials, but cost, performance, safety, and infrastructure challenges remain. More R&D and investment are needed to optimize biopolymer properties and scale up production.

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Biobased Materials

Supply Chain

Supply Chain

Are there disruptions in supply chain or transportation of materials that packaging companies need to be aware of?

The packaging industry faces several key transportation challenges:

  • First, e-commerce has led to a surge in demand for small parcel shipping, resulting in more trucks on the road to handle last-mile deliveries. This phenomenon has led to rising costs, emissions, and road congestion.
  • Second, packaging material shortages due to supply chain disruptions have made it difficult for companies to obtain adequate packaging. This can cause delays and force companies to use suboptimal packaging.
  • Third, lack of recycling infrastructure and inconsistent regulations across states create complexities in reverse logistics and recycling of packaging materials. Companies must navigate a patchwork of policies.
  • Fourth, demand for more sustainable packaging using renewable, recyclable, and compostable materials is growing. However, infrastructure to collect, sort, and process these materials is lagging in many regions.
  • Fifth, a shortage of truck drivers and warehouse workers has made it difficult for companies to meet delivery timelines. Attracting and retaining qualified personnel is an ongoing issue.

In summary, key transportation challenges include problems related to e-commerce shipping, packaging material shortages, inconsistent recycling policies, lack of sustainable packaging infrastructure, and labor shortages.

Companies are adapting through route optimization, sustainable packaging innovation, driver incentives, and automation, but overcoming these hurdles requires collaboration across the packaging value chain.

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Packaging Films

What research and development activities are happening in packaging films?

  • Biodegradable and compostable films: Several articles discuss research on developing biodegradable and compostable packaging films using natural materials like plant fibers and proteins. For example, scientists created biodegradable films from avocado peel fiber crosslinked with calcium ions. Researchers also developed a biodegradable coating/film using modified starch, succinic acid and chitosan. Companies like Xampla are developing compostable and edible films from plant proteins.
  • Active and antimicrobial films: Researchers are incorporating active compounds into films to extend food shelf-life. One study created films with coffee ground-derived carbon dots and grapefruit seed extract that displayed antimicrobial activity against food pathogens. Another developed starch-based films with antimicrobial properties.
  • Barrier properties: There are studies aiming to improve barrier properties against moisture, oxygen and UV rays. The avocado peel fiber films had reduced moisture absorption and permeability. Biopolymer coatings are being explored to improve water vapor barriers for paper-based food packaging.
  • Sustainable materials: Using renewable, biobased and recycled materials for films is a focus in some studies. Dow Thailand makes rice bags with recyclable mono-material plastics. Elopak launched aseptic cartons with plant-based polymers instead of aluminum. Xampla uses plant feedstocks to replace plastics.
  • Smart and active packaging: Incorporating sensors, QR codes, RFID tags for intelligent packaging is gaining traction. This type of technology can monitor freshness, enable tracking, and reduce food waste.
  • Recyclability: Enhancing recyclability of packaging films through materials selection, labeling and collection schemes is a priority. Films are now being designed to be easily recycled.

In summary, key R&D trends for packaging films include biodegradability, renewable materials, barrier properties, antimicrobial activity, intelligent packaging, and recyclability. The focus is on more sustainable and functional packaging films.

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Packaging Films

Recycling

Recycling

What challenges do brands face in adopting recycled-based packaging?

Brands face several key challenges in adopting recycled-based packaging.

First, there is a lack of infrastructure and demand for recycled materials, making them more expensive and harder to obtain than virgin materials. This poses difficulties in scaling recycled packaging, especially for global brands that require massive material volumes.

Second, recycled materials can present technical challenges, like contamination or inconsistent quality, that make them difficult to incorporate into packaging manufacturing processes designed for virgin materials. Brands must invest in R&D and equipment upgrades to accommodate recycled content.

Third, brands struggle to make recycled packaging look and perform the same as packaging made from virgin materials. Consumers expect consistency, but characteristics like color and odor can differ with recycled materials. Brands may need to educate consumers and conduct market testing before transitioning packaging.

Finally, the complex global supply chains of major brands present traceability and logistical challenges in sourcing recycled materials. Brands must develop systems to verify and transport recycled materials to worldwide production facilities. Overcoming these hurdles requires major investments in infrastructure, innovation, and strategic partnerships across the value chain. But leading brands are increasingly prioritizing recycled packaging to meet consumer and stakeholder demands for sustainability.

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