Flexible Packaging
Flexible packaging innovation is key to the circular economy of the future
he packaging industry has always looked to the future, but that focus is more pressing than ever. As each day brings us closer to environmental deadlines, from the UN Sustainable Development Goals’ 2030 target to the EU’s imminent Packaging and Packaging Waste Regulation, the industry is pushing to cut waste, emissions and plastic.
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Now that the second half of the 2020s is underway, these goals need to translate into tangible outcomes. Targets must be met and potential must be realised. For many applications, fl exible packaging remains a strong contender, supported by cutting- edge converting machinery, fi nishing techniques and value-adding technologies. Brands that partner closely with their packaging suppliers can develop optimised solutions that deliver results; not just today, but well into the future.
BALANCING PRODUCT PROTECTION AND SUSTAINABILITY
One of the most pressing challenges, especially in food and beverage packaging, is maintaining product protection while using renewable or recyclable materials. A basic paper bag made from recycled plant fi bres might be sustainable in theory, but it often falls short when preserving perishable foods that travel through long supply chains. This matters because food waste is a major contributor to climate change. UNEP estimates
that nearly a billion tonnes of food are wasted annually, generating around 8 to 10 percent of global greenhouse gas emissions. Plastics produce about 3.4 percent of total emissions, so while plastic reduction is important, preventing food waste can have an even more signifi cant impact. Flexible packaging is growing quickly because
it off ers a practical balance between functionality and sustainability for many applications. It is generally lighter and uses fewer materials than rigid alternatives, while still providing strong barrier performance. Its fl exible nature also means more packs can ship in a single consignment, cutting transport emissions.
Lightweighting has become a key trend, whether replacing rigid packs with pouches or swapping heavier polymer laminates for lighter grades. Even small weight reductions in each pack can add up, lowering costs and carbon footprints across an entire packaging portfolio. Of course, the right converting machinery is vital for producing these innovations at scale; ideas only matter if you can put them into practice.
DESIGNING RECYCLE-READY SOLUTIONS The term ‘fl exible packaging’ also refl ects its versatility in production, with converters able to add functionality, convenience and value to meet a range of requirements. For example, laser scoring technology can create lidding fi lms designed with
recycling in mind. Multi-polymer soft plastics have traditionally been hard to recycle, as mechanical recycling cannot separate diff erent polymers. This often results in lower-quality recovered material or contamination of other plastic streams. Laser scoring lets manufacturers produce fully circular trays for fresh produce by scoring micro- perforations into the lidding fi lm to create an easy-peel opening without extra plastic elements. When combining a monopolymer lidding fi lm weld-sealed to a matching monopolymer tray, the entire pack can be recycled as one unit, reducing consumer confusion and ensuring a more straightforward path to circularity.
LEADING IN LAMINATION
Packaging manufacturers have also turned to new lamination and coating techniques to make monopolymer materials more viable. Duplex, triplex and quadplex lamination give brands and retailers the fl exibility to tailor solutions for diff erent applications. Production lines can use multiple coaters and laminators to apply barriers that protect against oxygen, moisture and gas, using water- or solvent-based adhesives to balance performance and recyclability. In addition, paper-based fl exible packaging has become increasingly practical. Though paper has high recycling rates and is sourced from renewable materials, it traditionally fell short on barrier protection. Now, coatings and lamination mean paper-based materials can off er strong functionality while still being fully recyclable. Metallisation, high-barrier liners, water-based coatings and other enhancements help businesses reduce reliance on plastics without compromising product integrity.
These are just a few examples of fl exible packaging’s potential. Improvements in slitting, print fi nishing and ink technology allow for tighter production tolerances, yielding higher-quality packaging with less supply chain waste. Ongoing advances in barrier coatings and materials will likely make fl exible packaging increasingly compatible with future recycling needs.
For brands and retailers looking to achieve a more circular future, fl exible packaging provides a clear route. The technology is already in place and expertise continues to grow.
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March 2025
www.convertermag.com
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