Flexible packaging Sustainable flexible packaging
solutions for sustainable food By the Bak Ambalaj R&D Team
FOOD WASTE, PLASTIC POLLUTION AND THE NEED FOR SUSTAINABLE PACKAGING Sustainable food packaging has become one of the most critical research areas in recent years due to the increasing environmental impacts of food waste and plastic pollution. Rapid population growth, industrialisation and rising consumption habits have signifi cantly increased the amount of packaging waste generated worldwide, particularly in the fast-moving consumer goods (FMCG) sector. Conventional petroleum-based plastic packaging materials, which are widely used in food applications, persist in the environment for long periods because of their non-biodegradable nature, leading to serious environmental and ecological concerns. Therefore, the development of sustainable fl exible packaging solutions that can both preserve food quality and minimise environmental impact has gained considerable importance.
Flexible packaging is widely preferred in food packaging applications due to its lightweight structure, cost effi ciency, excellent printability, processability and sealing performance. Although fl exible packaging may appear as a single-layer material, it generally consists of multilayer composite structures combining diff erent functional layers such as printing surfaces, barrier layers and sealing layers. These multilayer systems are designed to protect food products against oxygen, moisture, aroma transfer, UV exposure and microbial contamination throughout their shelf life. However, the complex structure of conventional multilayer packaging systems creates major challenges in recycling processes because diff erent polymer types are diffi cult to separate effi ciently.
TRANSITION FROM CONVENTIONAL STRUCTURES TO SUSTAINABLE PACKAGING SYSTEMS
In response to increasing sustainability targets and circular economy strategies, the packaging industry has focused on developing recyclable mono-material structures and bio-based packaging alternatives. Mono-material fl exible packaging systems, such as mono-PE and mono-PP, are considered promising solutions for improving recyclability by reducing material complexity. In these structures, the required barrier performance is generally achieved through functional coatings, metallised layers, or barrier- enhancing additives such as EVOH-containing polyethylene fi lms and metallised BOPP fi lms. In addition to recyclable mono-material solutions,
bio-based and biodegradable materials are attracting increasing attention as alternatives to conventional plastics. Materials such as polylactic acid (PLA), polyhydroxyalkanoates (PHA), cellulose, starch and chitosan are among the most investigated sustainable polymers for food packaging applications. These materials off er advantages in terms of renewable sourcing and reduced environmental burden after disposal. However, the commercialisation of many bio- based materials remains limited due to challenges related to production costs, processability, mechanical performance and insuffi cient barrier properties for sensitive food products.
BARRIER PERFORMANCE AS A CRITICAL PARAMETER IN SUSTAINABLE FOOD PACKAGING
Barrier performance remains one of the most critical parameters in sustainable food packaging design. Oxygen transmission rate (OTR) and water vapour transmission rate (WVTR) values directly aff ect the shelf life and quality preservation of packaged food products. Conventional multilayer structures containing aluminum and PET layers generally
provide superior barrier properties, while recyclable mono-material structures often exhibit lower oxygen and moisture barrier performance unless supported by additional functional technologies. Similarly, standard PLA fi lms generally show insuffi cient moisture barrier performance for many food applications, whereas metallised PLA structures can signifi cantly improve oxygen and water vapour barrier properties. Recent developments in sustainable fl exible packaging technologies demonstrate that recyclable mono-material structures and bio-based packaging systems can increasingly meet the functional requirements of food packaging applications. Advances in metallisation technologies, barrier coatings, polymer modifi cation techniques and recyclable adhesive systems have enabled signifi cant improvements in both barrier and mechanical performance. These developments contribute to reducing plastic waste generation, increasing resource effi ciency and supporting circular economy objectives while maintaining food protection and reducing food waste.
FUTURE PERSPECTIVE ON SUSTAINABLE FLEXIBLE PACKAGING
Despite these advances, sustainable packaging systems still require further optimisation to fully replace conventional multilayer structures in all food applications. Future studies are expected to focus on improving barrier performance, mechanical durability, process compatibility and large-scale economic feasibility of sustainable fl exible packaging materials while ensuring compliance with recycling infrastructures and environmental regulations.
26
May/June 2026
www.convertermag.com
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