PACKAGING MATERIALS


range of paper-based hybrid solutions with different barrier levels and sealing options – heat or cold seal – designed to match specific requirements. For example, low-barrier applications, like coated products or products already in a protective wrapper, might only need a light paper-based option, while snack bars like granola or nut bars, may require high- barrier materials. Mondi works closely with its customers to understand specific product needs and also makes sure that the materials will also run well on packaging lines so there is no loss of speed or efficiency of the packaging operation. “In many instances of working with new customers, we have found that their existing packaging is more complex than necessary. Often it is discovered that a simpler, more sustainable hybrid packaging solution can offer the same shelf life, better recyclability, and strong branding potential,” says Paul.


Getting the right blend Jeff Minnette, Senior Director of Technology and Strategic Development at Jabil Packaging Solutions, explained more about the use of hybrid packaging in the food industry. “To meet the need for recyclable but functional plastic packaging, scientists and designers have had to create and innovate new materials,” he says. “Let’s say a material has a very high oxygen barrier but a very low moisture barrier – materials scientists are


36 • KENNEDY’S CONFECTION • JULY 2025


THE DECISION BETWEEN MONO- AND HYBRID-MATERIALS IS LIKELY TO REVOLVE AROUND TWO KEY FACTORS – PRODUCT PROTECTION AND EQUIPMENT COMPATIBILITY


now able to create a blend of additives that compensate for the characteristics that a substrate lacks.” Jeff pointed out that consumer behaviour


also needs to be part of the equation – is the product easy to compost? As do economic challenges – compostables are more expensive than traditional plastic – which that can limit the applicability of compostable packaging. “For the most part, it appears that CPG brands have turned their focus to package weight reduction, the use of post-consumer recycled (PCR) materials, and creating recyclable packaging,” says Jeff. Hybrid packaging solutions are growing in popularity today and can offer an environmentally friendly alternative to traditional plastic packaging. By combining materials, it is possible to reduce the plastic content.


According to Jeff, hybrid packaging allows


brands to create lighter versions of heavy packages and recyclable versions of already- lightweight packages, like pouches. Jabil Packaging Solutions, for example


can offer a hybrid package called FusePack, which combines the benefits of a lightweight flexible pouch and a rigid container. FusePack’s rigid interior frame defines the container’s shape and provides structural integrity, while the in-mould or paper panels enclose and protect the product as well as a traditional plastic container. “This combination of materials allows the package to be handled, sorted and reprocessed in a standard recycling centre or materials recovery facility (MRF). FusePack is smaller, and on average, 50-70% lighter than comparable rigid packs,” says Jeff.


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