Sustainable Converting
A holistic path forward for driving sustainability in packaging
By Sara Alexander, marketing & communication manager flexible packaging, BOBST
he push for sustainability in packaging is intensifying year after year and presents the industry with a complex challenge that has no obvious solution. Today’s printers and converters face pressure from regulators and customers alike to reduce waste, increase effi ciency, meet emerging regulations and deliver improved, environmentally responsible products to market. However, achieving these goals in isolation is rarely eff ective.
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To make meaningful progress, the industry must embrace a holistic approach that considers the full scope of sustainability, from operational practices and equipment upgrades through to the end-of-life phase of packaging product. By doing so, manufacturers and converters can uncover targeted opportunities for impactful change.
OPTIMISING OPERATIONS FOR SUSTAINABILITY
For manufacturers and converters, operational improvements are the most immediate and controllable route to sustainability. Benchmarking tools like third-party assessments such as EcoVadis are commonly used to benchmark sustainability performance and drive organisational progress. These eff orts translate into real benefi ts: a reduced carbon footprint and a stronger foundation for sustainable growth.
BOBST, has prioritised operational improvements with ambitious goals including achieving a 42 per cent reduction in operational carbon emissions by 2030. These commitments are already being recognised, with the company’s silver EcoVadis rating in 2024 placing it among the top 15 per cent of companies for sustainability excellence. However, it is important to remember that such accolades represent milestones rather than endpoints and must continue to lay the groundwork for further operational advances.
ADVANCING MACHINE EFFICIENCY Production machinery is another area ripe for transformation. High-volume converting machines pose signifi cant environmental challenges due to their energy and material consumption. While most emissions occur downstream in customers’ facilities,
BOBST is committed to helping lower these impacts by improving the effi ciency of its machines, with a target to reduce machine energy usage by 20 per cent by 2030 compared to 2022 levels. Innovations like ACCUCHECK – a 100 per cent inline quality control system – ensure only boxes meeting strict criteria are produced, drastically reducing waste. Extended Colour Gamut (ECG) technology streamlines color management, eliminating ink waste, cutting ink use by 30 per cent and reducing setup waste and time by up to 90 per cent. Solutions like Start&Go enable automatic job setup using minimal material, while linerless labels developed with Avery Dennison boost effi ciency by removing the need for backing. All support smarter resource use and less waste.
Upgrading and remanufacturing of existing
equipment also plays a signifi cant role in supporting environmental and economic goals. Retrofi tting with advanced components like enhanced standby energy modes and ventilation kits that recover waste heat can yield substantial energy savings. In addition, BOBST’s CM Service, a specialised remanufacturing and refurbishment program for corrugated board and folding carton machinery, breathes new life into older machines by equipping them with modern controls, motors and connectivity, rejuvenating performance while halving environmental impact compared to new builds.
MORE SUSTAINABLE PACKAGING SOLUTIONS Packaging materials remain under intense regulatory and consumer scrutiny. The industry is developing recyclable, mono-material and biodegradable options to replace complex traditional substrates. Recycle-ready products like BOBST’s oneBARRIER family of high-barrier mono-material substrates mark an important step forward, off ering alternatives to metallised polyester fi lms with proven recyclability. Other innovations – such as PrimeCycle’s transparent and opaque mono-substrates and FibreCycle’s recyclable paper-based, high-barrier structures – create more sustainable choices validated for recyclability. Expansion into BOPP and bio-based materials is underway, emphasising that the path to sustainable packaging must be as diverse as the products themselves.
THE POWER OF COLLABORATION Major progress in sustainable converting depends on collaboration – sharing ideas and coordinating action across the entire value chain. The most impactful advances now emerge from partnerships connecting material suppliers, machine producers, converters and brand owners. As new technologies move from the lab into commercial production, these collaborations are shaping a more sustainable packaging future.
BOBST’s journey highlights that real sustainability results from commitment, innovation and partnership. Lasting change depends on deepening collaboration and supporting diverse customer goals, paving the way for a greener industry.
28
October 2025
www.convertermag.com
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