The future of flexible paper-based packaging is bright, with flexible packaging papers predicted to enjoy annual average growth of over 4.5% by the end of the decade. This is primarily thanks to their sustainable properties, especially when compared with plastic packaging.

An expert survey, entitled “The future of packaging 2030”, has now corroborated this development. Baden-Württemberg Cooperative State University (DHBW) Heilbronn collaborated with Heidelberg on the survey.

The results indicate that paper-based packaging solutions will increasingly play a dominant role in Europe by 2030, as long as key technological and economic challenges relating to coated paper packaging can be resolved. The study is based on expert interviews with trade and industry decision-makers, who are underpinning the ongoing trend toward paperization – the substitution of plastic with paper – in the packaging industry.

According to Professor Carsten Kortum, who led the study and is also in charge of DHBW’s Business Administration – Management in Commerce degree program: “It’s not just a trend, it’s a systemic change driven by new regulatory pressure, rising environmental awareness and associated changes in consumer behavior, and technological innovations.”

PPWR acting as catalyst

The new EU Packaging and Packaging Waste Regulation (PPWR) sets ambitious targets for 2030. PPWR serves as a key driving force and something of a catalyst, especially for flexible paper and cardboard packaging. Besides harmonized standards, it places a clear focus on sustainability, resource efficiency, and the circular economy.

This includes banning certain single-use formats, making recycled content mandatory in packaging, and using standardized recycling symbols.

“The PPWR is putting trade and industry under significant pressure to act,” emphasizes Kortum. “There’s also a lack of clarity, though, so businesses are asking for transparent standards and economic incentives.”

Moreover, the regulation is speeding up the process of consumers coming to see packaging as a symbol of sustainability and brand responsibility.

Associated challenges

According to the study, although paper packaging scores highly in terms of sustainability, consumer image, and recyclability, it also involves major challenges. Plastic packaging is cheaper than fiber-based solutions in many cases. Plus, consumers are often unwilling to pay the additional cost.

What’s more, the need to fulfill important barrier functions for food products, beverages, cosmetics, and certain non-food items is stretching paper packaging to its technical limits. Paper does not act as a barrier to moisture, oxygen, or grease. Consequently, printers require either hybrid paper-plastic solutions or functional coatings for monomaterials. Such options still often result in limited sustainability, as well. The industry needs further technological innovations if paper packaging is to be a competitive alternative to plastic in all areas of application.

Technological and sustainable innovation

The cost-effective application of barrier coatings on an industrial scale plays a key role when it comes to the quality, reliability, and cost-efficiency of paper packaging. Heidelberg is therefore working with Solenis, a manufacturer of specialty chemicals, on developing a cost-effective process to integrate coatings for fiber-based packaging directly into the existing web flexo printing process using the Boardmaster press. This will enable barrier coatings to be applied and combined inline with register accuracy. The purpose of the collaboration between Heidelberg and Solenis is to optimally coordinate the individual components of the Boardmaster, the chemical composition of the Solenis barrier coatings, and all the associated process technology for the benefit of packaging producers. 

“Cost-effective technology innovations are vital if paper packaging is to replace plastic equivalents on a widespread basis. The inline production of coated paper packaging and the cooperation with Solenis to develop innovative varnishes and coatings therefore mean Heidelberg is a driver of paperization,” says Dr. David Schmedding, chief technology and sales officer, Heidelberg. “That also makes us a systems integrator in the attractive growth market of mass-producing folding cartons.”