Page 13 - Packaging News magazine March_April 2023

already commercially available. These can give a much better print surface for brand graphics, finishes and embellishments; making them a preferred option in standard and premium FMCG segments.
Currently around 80% of car- tonboard is used in folding carton applications. Across the next five years, the most promising appli- cations will be found in primary food packaging as an alternative to single-use plastics. These are not a universal solution, and brands contemplating a switch need to carefully gauge the need for addi- tional features like functional coatings or internal liner bags.
In 2023, some of the fastest devel- opments will come in confectionery, with brands opting for folding car- tons, as well as flexible papers, in place of polymer pouches.
LIQUID PAPERBOARD
Aseptic cartons formed from liq- uid paperboards are made from laminating paperboards with polyethylene (PE) film or alu- minium foil on one or both sides. This presents a high barrier to the liquid and allows a majority paper- board pack to be used for a variety of wet foods, milk, milk substi- tutes, fruit juices, yoghurts, and other liquid foods.
While both the paperboard core and aluminium are widely recycled, liquid paperboard is the fibre format that presents the most problems in terms of recov- ery at end-of-life. The challenges of separating the two materials cost-effectively means these are rarely recycled. Liquid paperboard
suppliers have set up their own trial recovery schemes for existing formats, but availability is very lim- ited, in one of the smaller segments of the paper packaging market.
In response, several manufac- turers – Elopak, SIG Combibloc and Tetra Pak – are trialling new constructions without an alumin- ium layer for all products. These instead rely purely on PE barrier layers, that are easier to sepa- rate in mixed recycling schemes. Other R&D priorities include developing coatings from micro- fibrillated cellulose (MFC) or new biopolymers, such as polyethylene furanoate (PEF).
FLEXIBLE PAPERS
With flexible plastics increasingly recognised as the least recyclable material sets, there is potential for the latest generation of specialty papers. Several of these are being marketed as direct replacements for plastics, but there are multiple technical challenges, around bar- rier performance, processability, heat sealing, and printing.
These are being tackled pro- gressively, but the actual market displacement of flexible plastics will be limited over the Smithers forecast period. High-barrier paper lines are available, including retort- able pouch designs, but adoption in developed markets will be largely eclipsed by growing use in devel- oping regions. In nascent markets, where retail and waste collection structures are more basic, these still present the best option, espe- cially when cold chain distribution and home refrigeration is limited.
Top: Corrugated cardboard is still the most significant fibre pack type. The 10:PM Mattress Box by Production Packaging Innovations is a PIDA 2023 finalist.
Above: PulPac is making strides in moulded pulp packaging, like this paper bottle created with PA Consulting as part of The Bottle Collective.
Opposite: Fresh produce is a growth market for fibre. The Vitor Grapes ‘hippie punnet’ by NAVI Co Global is a PIDA 2023 finalist.
MOULDED FIBRE
Some of the most exciting develop- ments in fibre packaging is coming from moulded pulp or fibre, with Europe a hotbed for innovation. This material has traditionally been limited in use to egg cartons and protective shipping components. These are sustainable as they can be made with up to 100 per cent recycled content, are cheap, fully recyclable, and even if they are not collected, biodegrade naturally.
The main commercial advan- tage is that as a moulded technology these can start to replace formed plastics in tray, tub, and even potentially, bottle formats. For primary packs, bar- rier performance and resistance to oven or microwave cooking are priorities for technical R&D. The other main challenge is to develop moulded-fibre forming lines that can match the speed of existing thermoformed plastics. ■
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INDUSTRY INSIGHT