By Treijon Johnson, Director of Sustainability, Accredo Packaging

As the packaging industry works toward a lower-carbon future, material innovation has become one of the more powerful tools for change. Every stage of the packaging life cycle, from resin production to disposal, carries a carbon cost. For converters and brand owners alike, the challenge is to reduce that cost without compromising the performance, functionality or visual impact that packaging must deliver.

Throughout the past few decades, consumers have become increasingly aware of the packaging industry’s environmental footprint, sparking global concern. Packaging companies have had to shift their focus and begin to rethink material sourcing and design. Now, converters are increasingly looking beyond traditional fossil-fuel-based plastics and exploring renewable and more recyclable alternatives that can maintain production efficiency while helping lower greenhouse gas emissions.

Rethinking packaging from the ground up

One of the most significant developments in this area has been the rise of renewable, plant-based resins. Sugarcane-based resin is now being used as a near drop-in replacement for conventional fossil fuel-based polyethylene plastics. Since sugarcane absorbs carbon dioxide as it grows, these bio-based resins can offer a lower carbon footprint compared to conventional fossil fuel-based polyethylene, based on life cycle assessment, over the product’s life cycle.

Companies like Accredo Packaging have integrated bio-based materials, such as sugarcane, into their flexible packaging structures, demonstrating that renewable materials deliver nearly the same material properties and performance as conventional fossil-based polyethylene, functioning as a drop-in replacement. LCAs published by Braskem show that sugarcane-based polyethylene can achieve a net negative carbon footprint due to biogenic carbon uptake during sugarcane growth. Actual results may vary by application.

 For converters, this creates an opportunity to work with materials that can help to meet sustainability targets while still running efficiently on existing printing equipment. The growing availability of bio-based polymers also helps diversify resin sourcing, adding resilience to supply chains that have historically relied on petroleum inputs.

Designing with circularity in mind

Reducing carbon emissions is not just about the materials used but also about what happens to them after use. Designing packaging for circularity has become a central focus across the value chain. This approach encourages the use of mono-material structures and simplified laminations that are easier to recycle through existing collection systems.

Flexible packaging that uses a single type of polyethylene, including bio-based polyethylene, for instance, can be recycled through store drop-off programs where available. Simplifying materials in this way makes recovery more efficient, allowing the plastic to be reprocessed into new products and keeping valuable resources in use rather than wasted.

Lightweight and resource efficiency

Advances in resin and film technologies have also made it possible to reduce the amount of material required for each package without sacrificing protection or visual appeal. Using lightweighted films not only decrease the raw material needed but also reduces energy consumption during manufacturing and transportation.

This concept has gained traction among converters seeking to balance cost savings with environmental benefits, including reduced material use and lower transportation emissions. Facilities that focus on precision extrusion and film engineering have demonstrated that thinner gauges can achieve the same functionality as heavier laminations, offering both performance and environmental advantages.

Measuring impact and setting new standards

The conversation around carbon reduction is becoming increasingly data driven. Companies can no longer rely solely on assumptions or general sustainability claims. They need concrete metrics to track progress and make meaningful improvements. Life-cycle assessment (LCA) tools are helping companies measure emissions and resource use at every stage of packaging life, from raw material sourcing and manufacturing to transportation and end-of-life disposal. This approach allows converters and brand owners to identify the most effective strategies for carbon reduction, whether through smarter material choices, design improvements, or process optimization.

Equally important is transparent reporting. 75% of consumers view brand transparency as essential and are willing to switch to brands that prioritize it. As both retailers and consumers increasingly expect evidence behind sustainability claims, clear documentation of a package’s environmental impact has become a key part of packaging strategy. Sharing data on materials, design, and manufacturing practices allows companies to demonstrate measurable progress while strengthening trust and credibility with their customers.

A smarter path forward

Reducing packaging’s carbon footprint requires collaboration, innovation, and a willingness to rethink long-held assumptions. Smarter material choices, whether through renewable feedstocks, more recyclable designs or lightweight structures, represent the most direct route toward meaningful change.

As converters continue to balance performance requirements with environmental responsibility, the shift toward renewable materials and circular design will play an increasingly central role. The companies investing in these innovations today are setting the foundation for the next generation of more sustainable packaging versus traditional, one that meets the demands of the market while helping preserve the planet’s resources.

About the author: Treijon Johnson is the Director of Sustainability at Accredo Packaging. He leads climate strategy, packaging innovation, and circularity initiatives across North America and Asia. Recognized as a Circularity Emerging Leader, Trei advocates for equitable, science-based solutions that drive measurable progress toward a low-carbon, waste-free future.