Paperization: Is paper packaging the more sustainable choice?

In the pursuit of more sustainable solutions, more and more food producers are considering using paper packaging, as consumers perceive paper as environmentally friendly. The trend toward fiber-based packaging can be seen in various innovative prototypes, from paper bottles to special cardboard packaging. But is paper packaging really the more sustainable choice? In our three-part blog series on paperization, we take a look behind the scenes and, in this first part, put assumptions and myths about paper packaging to the test.

Ideally, modern packaging should be a jack-of-all-trades: It should provide the best possible protection for the product as well as being practical to use, appealing to the touch, visually striking, cost-efficient, and environmentally friendly. The latter, in particular, has become much more critical in recent years: More and more consumers are paying attention to sustainable purchasing and scrutinizing packaging closely. Political pressure is also increasing: The PPWR, the EU’s Packaging and Packaging Waste Regulation (see page 16), is the latest step toward promoting a circular economy and drastically reducing packaging waste. Therefore, companies are inevitably looking for environmentally friendly packaging solutions. In the pursuit of greater sustainability, more and more food producers and retail chains are turning to paper packaging – or, more precisely, to fiber-based packaging. We’ll come back to this later.

“Paperization” is the name of the trend in which attempts are being made to replace plastic with paper in the packaging sector. At first glance, the move seems almost logical. After all, paper has a good image in society. The material is considered a renewable raw material and is thus perceived as sustainable and environmentally friendly. It has a pleasant feeling and can be designed to attract attention. The positive ecological perception among the population and the image that companies are only too happy to adopt for their own products are big reasons why paperization is booming.

The advantage of paper as a material is that it is made from a renewable raw material and can decompose under natural conditions. However, paper only decomposes optimally if it is not overloaded with food waste or other contaminants. Ensuring that the paper used comes from sustainable forestry is also important. This is because paper loses its ecological benefits and can contribute to the destruction of forests and associated ecosystems if it is not sustainably sourced. Furthermore, extracting fibers and producing pulp is an energy and resource-intensive process. In the EU, the USA, and China, a large proportion of the primary fibers used are imported, which means that the ecological impact of paper production is often shifted to countries such as Canada or Brazil. Recycled paper has a better environmental footprint than paper made from virgin fibers: It protects forests and requires less energy and water. One disadvantage of paper packaging is that it runs more slowly in filling plants than plastic packaging. This is a significant drawback, especially in the dairy industry, where huge quantities are filled, as a slower filling process can significantly reduce efficiency and productivity.

Paper is also neither water nor grease-resistant. It therefore needs an appropriate coating for drinks or moist food. A plastic coating extends the shelf-life of packaged food, but makes recycling much more difficult and costly. At first glance, coated laminates are perceived as paper, so consumers are often unaware that they are holding packaging with a significant plastic content. It is precisely this type of coated paper and cardboard packaging that is included in the fiber-based packaging category. For the sake of completeness, it should be mentioned that fiber-based packaging also includes traditional corrugated cardboard boxes, paper bags, etc., in addition to coated paper and cardboard packaging. However, the fiber-based packaging category also includes cardboard-plastic combinations, i.e., plastic cups with a cardboard sleeve, as these generally meet the requirement of at least 50% fiber. In contrast to coated paper packaging, the two recyclable materials cardboard and plastic can be easily separated in cardboardplastic combinations.