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Pioneering sustainable solutions: the future of food-safe packaging
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onsumer expectations, legislative pressures, and brand commitments are all converging to accelerate the shift toward sustainable, food-safe packaging. For converters, this presents both challenges and exciting opportunities to lead innovation in sustainable materials, technologies, and processes. One notable trend is “paperisation” of plastic packaging, where the converting sector plays a critical role in developing fi bre-based, recyclable alternatives. One of the major hurdles is eliminating non-recyclable components from paper-based packaging, such as laminated fi lms, plastic trays, or inner linings, while ensuring the pack retains its protective qualities and meets stringent regulatory requirements for food contact.
To enable cartonboard and paper-based packaging formats, performance enhancements are key. New developments in direct food contact (DFC) barrier coatings, water-based heat seal varnishes, and printing inks are essential in delivering functionality.
Sun Chemical, for instance, has focused on natural, water-based barrier coatings that are compliant with DFC standards, off ering excellent sealing and barrier properties. These coatings allow converters to deliver packaging that meets food safety regulations while reducing or eliminating the need for plastic-based elements. Lightweighting is another critical area. By
As global concern over environmental issues grows,James Buchanan, product director, sheetfed systems, Sun Chemical, says the packaging industry stands at the forefront of reducing the amount of board used without
compromising pack integrity, converters can help lower material consumption and carbon emissions. Converters are uniquely positioned to integrate sustainable materials into production lines and reimagine packaging construction. They are also essential in helping brands meet recyclability and circular economy goals. Product solutions such as Sun Chemical’s DFC inks and barrier coatings are enablers in achieving these targets. They are tailored for fi bre-based substrates to enhance compliance and environmental performance. They are tailored for fi bre-based substrates to enhance compliance and environmental performance. A specifi c example of impactful change in the packaging space is Sun Chemical’s work with Qualvis. This collaboration led to the redesign of a mixed-material 920g Truffl e Chocolate carton for Whitakers, where plastic elements like shrink fi lm, plastic extrusion layers, and PET clamshells were replaced by fi bre-based tear strips and internal holding structures. Sun Chemical’s DFC-compliant inks (SunPak DirectFood Plus) and barrier varnishes (SunStar SunSpec) played a key role in replacing the plastic with recyclable, food-safe solutions that allowed premium print on the inside of the carton for branding and information.
This concept has now been commercialised across multiple Whitaker’s product lines, demonstrating that cartonboard converters can
deliver scalable, sustainable solutions without sacrifi cing functionality or brand impact. Sustainability isn’t just about materials – it’s also about production effi ciency. Cardbox Packaging, another forward-thinking converter, adopted Sun Chemical’s SunPak FSP EcoPace low migration inks, which off er high productivity, low misting, and excellent print quality at high speeds. With bio- renewable carbon content (BRC) of up to 84%, these inks support environmental goals while maintaining pressroom effi ciency.
Converters committed to sustainability are increasingly aligning with third-party standards and certifi cations. Qualvis, for instance, sources materials in compliance with Forest Stewardship Council (FSC) standards and off sets carbon emissions through the World Land Trust. Combined with their adoption of DFC technologies, this has enabled them to achieve a net-zero carbon footprint status for their packaging operations.
Similarly, Sun Chemical’s SunPak FSP EcoPace ink range has achieved the Cradle-to-Cradle Certifi ed Material Health Certifi cate at the Platinum level. The shift toward sustainable cartonboard packaging requires a collective eff ort between ink and coating suppliers, converters, and brands. Sun Chemical’s 5R framework – Renew, Redesign, Recycle, Reduce, Reuse – focuses not only on replacing materials but rethinking how packaging is designed and manufactured.
Sun Chemical’s mission is to provide converters with solutions that enable sustainable packaging transitions occurring throughout the market. Whether through high-performing inks, barrier coatings, or print enhancements, the goal is to future-proof packaging with food safety and sustainability at its core.
Converters are critical agents of change in the packaging value chain. With advanced technologies, strong supplier partnerships, and a commitment to sustainable practices, the converting industry is reshaping what’s possible with cartonboard and paper.
Through continuous innovation and responsible sourcing, converters are helping brands reduce their environmental impact while still delivering safe, high-quality packaging solutions to market.
12 June 2025
www.convertermag.com
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