Exploring Recyclable Flexible Packaging Trends Using Polymer-based Materials
When we think about packaging materials, we overwhelmingly think about paper, cardboard, plastic, glass, and aluminum. The problem is that most businesses think the same way even though there is a world of other options outside of these common packaging materials. Seeing the word polymer can discourage some from learning more about eco-conscious packaging solutions, even though paper, cardboard, and plastic are examples of polymers. Research around polymer-based materials is focused on creating biodegradable polymer packaging materials that mimic these common material’s properties without having to depend on non-renewable resources and fossil fuels. This article will demystify the term and impress some of our passion for the ongoing research and why it matters.
What are polymer products?
Polymer products are any products made of chains of repeating combinations of molecules. Essentially, it involves any pattern that creates a solid raw product.
Polymer research is essential to create earth-friendly, high-barrier polymer packaging. Creating polymer packaging products that reproduce the properties of plastic while being completely biodegradable has become a significant field of research and funding for innovation, championed by China, Thailand, and Germany, with a focus on polymer packaging bags, polymer protective packaging, polymer packaging materials, and polymer for food packaging.
Which natural polymer makes up paper?
Polymers can be naturally occurring, such as the DNA found in animals and the cellulose in plants and paper, or synthetically made by humans to make plastic, adhesive, and fibers. Wool and silk are other examples of naturally occurring polymer products.
What are polymers used for?
Polymer packaging for exports has made significant strides in innovation by replacing packing peanuts made from unrecyclable polystyrene with seemingly identical packing peanuts made entirely from cornstarch. Their main benefit is their ability to dissolve in warm water, leaving zero waste. Polymers are used to create a solid structure that can be used towards different means depending on the need of the product. Polymers have a wide array of applications, with significant funding going towards the development of sustainable and eco-friendly packaging for transport, food, beauty, and e-commerce in general.
Top Sustainable Packaging Statistics
The five main packaging areas expected to grow most are eco-friendly packaging, digital printing, e-commerce packaging, polymer flexible packaging, and “SMART” packaging (ex, using QR codes to be sorted by machines).
Sustainable Packaging Market Size 2024
The packaging industry as a whole is forecasted to grow by 3% each year until reaching $1.3 trillion by 2028. The fastest growth is expected in the bioplastic and biopolymer sectors, as finding biodegradable polymer substitutions to polyester has seen mounting pressures from governments, supported by policies such as country-wide bans of certain single-use plastic items. Compared with the global industry’s 3% growth, biodegradable plastics are expected to grow 9.7% yearly from its $4.1 billion market share in 2021.
The Best Materials For Eco-friendly Packaging
The recycling challenges have made starch-based polymer products that can decompose independently see the fastest growth in e-commerce and food packaging, with market shares currently owning 40% of the biodegradable plastics category in 2021. Outside of packaging, starch blend manufacturing has expanded in various industries, namely, vehicles and agriculture.
Bioplastics requiring specific recycling environments, such as PLA and PHA, have succeeded by targeting biomedical applications and agriculture. The higher cost of production of certain materials, such as PHA, has also made expanding into packaging for food and drink and consumer goods less accessible but has seen success in the applications of hot beverages.
The most accessible way for companies to invest directly in eco-friendly packaging is to use recycled paper and cardboard wherever possible and focus on compostable materials.
biodegradable polymer food packaging
To tackle the problem of plastic pollution, SCGC Thailand created the SCGC GREEN POLYMER™, considered a bioplastic. This renewable resin-based resource is fully compostable from a flexible plastic-like bag for the household and industrial sectors. DIN CERTCO from Germany certified the bio-compostable compound as industrially compostable at 60 degrees Celsius from bag to carbon dioxide, water, and biomass in 180 days, positioning Thailand as a leader in innovations for sustainability.
Outside of starch-based bioplastics, other polymer packaging using more common base materials that show great promise are biodegradable plastics made from sugarcane, bamboo fibers to make rayon fabric, furniture and packaging, mushroom-based packaging foam, and seaweed-based packaging.
Why is product packaging important?
Following initiatives by SGCG with some clients to reduce individual packaging weight, finding ways to reduce your product’s packaging footprint without reducing its durability is a great way to increase sustainability. Optimizing transport packaging size and weight to take up less space than needed will help reduce travel emissions and disposal.
One of the top ways the beauty and household industries can reduce pollution is to focus on reusable packaging instead of single-use plastics or bottles. Any product that needs to be bought repeatedly can reap huge benefits from an initial investment in research and development to create refillable products with higher-end packaging that can last a lifetime.
While the EU holds the highest packaging and plastic recycling levels, plastics are still only recycled at a rate of 40%, and many other countries need to catch up, with too much non-compostable packaging still ending up in landfills and the ocean. The quick rise of flexible packaging has also made recycling more of a challenge due to the mix of non-compatible layers of materials that cannot be separated. Using only compatible layers, like SGCG Thailand’s initiative for maximum recyclability, is an excellent example of how manufacturers can make their packaging more eco-friendly without investing in new materials or technologies.
Manufacturers can also make their packaging more eco-friendly by implementing sustainable production practices, such as waste management methods, “SMART” packaging, and switching to renewable energy. Upgrading to “SMART” packaging can also optimize distribution, transportation, and storage.
Pros and Cons of Eco-friendly Packaging
Bioplastics and biodegradable polymers need to be cross-integrated in those five areas to overcome the challenges of the technology. The similar properties of bioplastics compared to plastic make differentiating between both for recycling in general waste management impossible. The biodegradable properties of the biopolymer products would not necessarily be beneficial outside of a recycling system as each material often requires a specific environment, such as heat, to decompose. Waste management, “SMART’ packaging, and eco-friendly packaging would need to partner together to create QR codes for bio-plastics that could be sorted by machines at waste management centers so they could be disposed of properly. Bioplastics that come with these challenges also cause additional greenhouse gases to be released into the environment, meaning that more tracking is needed to evaluate the net benefit of these new polymer products. One clear net benefit, regardless of the cost or recycling opportunities, is that bioplastics are produced without using fossil fuels as a base material.
What’s the takeaway?
Instead of sacrificing product quality to meet profit margins, reviewing product packaging design strategies is the most impactful way to maximize every aspect of your business. On top of directly reducing your overall long-term production, storage, and shipping costs, it also provides positive psychological and financial benefits to your customers. Focusing on reusable and refillable packaging allows you to charge more, as surveys have shown that customers are willing to spend more on what they consider an investment instead of a sunk cost. Offering reusable packaging also helps to build brand loyalty as customers have to buy refills for your product. Focusing on recyclability by using mono-materials or mixing only materials with the same recycling requirements can be one of the easiest ways to make a positive change now in support of the new polymer research for more sustainable materials. Using compostable polymer packaging materials is the next step toward genuine environmental packaging.
To learn more about the plastic crisis and why you should care more about the research around biodegradable polymer flexible packaging materials, read my article, “Addressing the Plastic Crisis As A Materials Scientist.”
