Paper-Based Packaging is Having a Major Moment

Look out plastic—paper is gaining ground thanks to its increasingly eco-savvy sensibilities.

Paper-based packaging has always had an innate capacity for flexibility and cost-efficiency, and recent measures in responsible sourcing and recycling coupled with innovation in decorative customizations have lifted its reliability and visibility to make it much more than a “secondary packaging” material.

A March 2023 report from Future Market Insights estimates that the global paper packaging market will be worth $3.8 billion USD by the end of 2023—rising to $5.7 billion USD by the end of 2033 with an increased CAGR of 4.1%.

Paper-based packaging that is lightweight, easily recyclable and biodegradable, makes it an essential element of packaging. It also helps that increased consumer consciousness surrounding sustainable packaging, plus stringent laws introduced by several environmental protection agencies, have helped spike sales, which have also been driven by a robust jump in online shopping and delivery-on-demand services.

Eco-Forward Applications

Generally speaking, the demand for eco-friendly and responsibly sourced packaging has compelled every player in the process—from paper mills to retail brands—to reevaluate their supply chains, operations and packaging materials.

Harmony Paper was an early adopter of the sustainability movement and has developed a range of specialty papers that are certified recyclable and plastic-free. “We’ve focused on creating and reinventing the way specialty papers are being manufactured and used for virtually every application, ranging from folding cartons to rigid boxes, bags, labels, molded pulp trays, and even store signage and displays,” says Anthony Grinnell, Harmony’s CEO.

Harmony Paper’s EcoFX metallized holographic paper line is plastic-free and certified recyclable. The company additionally offers eco-friendly, certified recyclable Diamond Silk Glitter and wood pulp alternative bamboo, sugarcane and hemp papers, and also has 100% sugarcane pulp molded trays in lieu of traditional plastic options.

One of Harmony Paper’s most exciting recent product launches is its Pixie Paper line, a metal- and plastic-free “visual mix” of metallic, pearl and glitter that’s certified recyclable, made with biodegradable materials. It is available on wood pulp alternative base papers, such as sugarcane and bamboo. Grinnell says it’s ideal for folding cartons, box wraps, bags and labels.

Harmony Paper utilized Pixie Paper to create a folding carton it produced for a CBD product. “The base paper is a 16pt, 100% bamboo pulp with our proprietary Pixie Paper coating in gold,” Grinnell explains, adding that decoration consisted of soy-based inks, water-based varnish and gold foil stamping. “This folding carton is an excellent representation of how sustainable, eco-friendly packaging does not have to be boring. In fact, with the use of the 100% bamboo pulp base paper, this folding carton actually exceeds the sustainability of regular wood-pulp-based materials.”

The most important trend related to sustainability, according to Ben Cohen, chief marketing officer, Knoll Printing and Packaging, is recyclability as it relates to regionalization of production. “Over the last few years, many of the largest brands have communicated their sustainability goals externally, and those milestones are quickly approaching,” he says, noting that his company has developed propriety automatic machinery with seamless “Knoll-Quality” and is currently in production in Europe and in Knoll’s fully owned factory in the Philippines. “These sustainability parameters are sparking a new generation of innovation that is sustainability-conscious and will take our industry into the future.”

Knoll Printing and Packaging is an FSC-certified rigid box supplier and its Ecoform molded pulp remains one of its most in-demand sustainable materials, says Cohen. Launched five years ago, Ecoform is a plant-based replacement for plastic platforms made from bamboo, wood and sugar cane fibers. It is certified recyclable in the paper recycling stream, and can be custom molded, cut to order and color matched.

The House of Penhaligon’s partnered with Knoll Printing and Packaging to launch a new “industry-first fragrance coffret” that combines Knoll Ecoform molded pulp and FSC Paper and Board. The exterior of the set utilizes Knoll Ecoform molded pulp, which is shaped to resemble the iconic Penhaligon’s bottle, and is color-matched to Penhaligon’s signature green with a smooth, luxury appearance that dovetails with the brand’s DNA.

The interior features an FSC paper and board platform, which securely holds eight 10ml glass vials of Penhaligon’s “fragrant delights.” The platform features an innovative “pop-feature” which elegantly displays and protects the fragrance collection while making each vial easy to retrieve. The finishing touches include a uniquely British ribbon, which keeps the set closed and adds a bold pop of color, as well as a label that displays the name of this packaged set. Cohen says this is the first time Knoll Ecoform molded pulp and FSC paper & board have been engineered in this way, “and demonstrates Knoll Printing and Packaging’s commitment to setting new standards for luxury sustainable packaging.” 

The company also recently launched a patent pending, 100% Knoll Ecoform compact that is plastic-free and magnet-free. Cohen says it will be introduced onto the market by “some of the most notable brands” next year. “The unique patent-pending design took over a year of research and development to launch onto the market,” he says. “The compact has a smooth luxury feel and finish, and is fully customizable, including embossing and stamping, or added FSC paper mask for additional decoration.” He adds, “The most groundbreaking element of the design is a magnet-free closure and removable mirror.”

At Unimac Packaging, environmental commitments are baked into the company’s DNA. As a member of Sedex, Unimac is FSC, SFI, PEFC and ISO certified 14001:2015 for environmental management, has a plant-wide paper waste and recycling system, and utilizes renewable energy through its solar-powered roof to generate 25% of its energy.

“For clients looking for sustainable options, we recommend and offer paperboard that contains recycled content, from CRB to SBS and other commercial stocks for folding cartons as well as FSC and SFI certified boards,” says the company’s Maria Lacher, vice president of sales, “noting that the company also has an ink room on premises with eco-friendly inks that include plant-based ingredients. “The current push from our clients is eco-conscious sustainable packaging without forfeiting the decorative effects that help the products pop on the shelf. We are able to print on recyclable foil board that has a 19 out of 20 total pts for recycling.”

Unimac recently worked with InterParfums to create paperboard packaging for their Hollister Canyon Collection fragrances—Canyon Escape, Canyon Rush and Canyon Sky—launched in 2020, 2022 and 2023, respectively.

“InterParfums consistently pushes the envelope for innovative design that incorporates sustainable solutions,” explains Unimac’s Michele Murphy, business development manager. “The client was looking for an eco-friendly paper (SFI certified) that offered a smooth surface for high-quality print output, as well as decorative effects for their secondary packaging.”

Unimac created 30-, 50- and 100ml package sizes for each fragrance using 18pt C1S (SFI certified) board. Two complimentary PMS colors were applied for each version, along with spot gloss coating to contrast with a matte UV varnish plus an embossed Hollister logo and fragrance name.

Made for Maximum Appeal

In light of paper-based packaging’s ongoing sustainability refinements, decorating and finishing techniques and applications have also been revamped to tow the same eco-conscious line. “In today’s market, environmental responsibility is becoming the norm and consumers expect it,” comments Joe Cicci, president emeritus, CO II Packaging.

CO II has developed Lustre-look and Natra-look processes to help achieve quality and attractive decoration while meeting the eco-friendly goals of its brand customers. The company is also now offering inline coatings with Biolithe, a patented, natural, low-cost coating additive that Cicci says can dramatically reduce the emission of methane gas during decomposition in a landfill. “It provides an easy sustainability win solution with immediate benefits,” Cicci says.

In a nutshell, Biolithe works by uniquely prohibiting methane from being produced while continuing to allow paper to break down at its normal rate. According to Biolithe Inc., the company behind the eponymous innovation, the process boils down to selectively helping specific microbes outperform methanogen microbes. When Biolithe is applied to paper and paper products, it provides essential nutrients to methanogens’ microbial competitors, depriving the methanogens of the organic compounds they need to perform normally, thus curtailing their ability to produce methane.

For brands wanting to make a visual impact with their folding cartons and rigid boxes, Case Makes, which offers plastic-free options and water-based adhesives and lacquers, recently launched a fully recyclable transfer product called LuMet that’s positioned as an environmentally friendly alternative to conventional aluminum foil and film laminates used for health and beauty packaging, folding cards and rigid box wraps. It’s certified as fully recyclable by Western Michigan University and was designed and engineered for sustainability without having to sacrifice performance or appearance.

“We’ve been hard at work with our mill partners to do all we can to continue the circularity movement and offer products that are plastic-free and 100% recyclable and re-pulpable, such as LuMet,” says Gregg Olah, the company’s sales manager of specialties. “The absence of film allows for better yields for printers and reductions in shipping costs [and] it’s as printable, stamp-able and glue-able as paper, making the design opportunities endless.”

Arkay is another company that’s found increased success amidst the convergence of innovation and sustainability. “We are proud of the way we can keep the allure of a beautiful design using sustainable materials to get there,” explains Ruth Rugoff, chief communications officer. “Arkay is unfazed by any increased demand for eco-friendly and responsibly sourced packaging, and we are fulfilling this need based on each of our customers’ requirements.”

Having recently attained Platinum certification from EcoVadis, the company’s latest innovation is called Paint on Press. This process was devised to help “reveal all of the true graphic possibilities contained within our customers’ artwork,” Rugoff says. “Adhering to specific steps, this process enhances the artists’ design concept, while working to develop the most cost-effective production methodology.”

And lastly, European specialty paper producer Fedrigoni added to its existing Symbol Card SBS collection in April with Symbol Pack, which was created in response to an increase in demand for quality boxes to elevate the unboxing experience in premium beauty and cosmetics applications. (The product is also ideal for foods and beverages because it is Food Contact Certified by ISEGA.)

The new collection comes in two shades--Premium White (a bright white) and White (a softer, natural white).

Symbol Pack comes in a variety of weights (230, 250, 310, 330, 360 and 400 g/m2) and is made for superior folding durability. Fedrigoni says the quality of the papers’ raw materials gives it “excellent color-fastness to light and delivers top performance with hot foiling, embossing, laminating and varnishing.” Furthermore, it is made from virgin pulp, making the paper completely biodegradable and recyclable while also being able to achieve a clean die-cut, and maintaining a smooth coated surface to achieve high level detail for image printing.

“Symbol Pack brings a new level of versatility to the Symbol Card family that we’re excited to see unfold,” says Ian Braithwaite, Fedrigoni UK’s commercial manager. “We have carried out research and developed solutions for years in order to reduce the environmental impact of our supply chain, so we’re inspired to continue creating products like Symbol Pack that are able to seamlessly enter the circular economy.” BPhigh demand for items from secondary cartons to bags and labels. New advanced deco processes add dimension & allure without compromising sustainability.

Envirotray Offers A New Alternative to Traditional Vacform Box Inserts

Boxed gift sets are a tailored way for brands to present a curated selection of products, whether they are promoting a fragrance and flanking products or showcasing a complete color cosmetic or skincare regimen. But at a time when brands are doing their best to make more environmentally conscious packaging choices, a plastic-free alternative to traditional vacform box inserts has emerged that secures gift box contents in a completely sustainable way.

The Envirotray from General Fibre Products is comprised of FSC paper, and according to Jay Tarantino, the company’s vice president of sales, the innovation has already removed more than 350 tons of plastic from the waste stream.

The company works directly with brand owners as well as set box/folding carton companies to design an Envirotray to protect and secure beauty and personal care products, then secondary set boxes and cartons are created around the configuration. Envirotrays are custom designed and finished in-house at General Fibre’s manufacturing facility in Long Island, NY. 

Since receiving a patent on its Envirotray last year, Tarantino says his company has experienced an uptick in beauty and cosmetic industry use of the Envirotray as a preferred insert and replacement for plastic vacforms in gift sets, both in folding cartons and set boxes.

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