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According to a survey by HEIDELBERG, the flexible papers market will grow yearly by over 4%, but the technology needs to be developed further to properly replace plastic packaging
Flexible papers will see an annual average growth of over 4.5% by the end of the decade, according to a new study released by print press manufacturer, HEIDELBERG.
The survey, entitled “The future of packaging 2030”, was conducted by Baden-Württemberg Cooperative State University (DHBW) Heilbronn in collaboration with HEIDELBERG.
The study is based on a range of interviews with trade and industry decision-makers, aiming to highlight the ongoing trend toward ‘paperisation’ – the substitution of plastic with paper.
The results indicate that paper-based packaging solutions will increasingly play a dominant role in Europe, as long as key technological and economic challenges relating to coated paper packaging can be resolved.
According to Professor Carsten Kortum from DHBW’s Business Administration department, who led the survey: “It’s not just a trend, it’s a systemic change driven by new regulatory pressure, rising environmental awareness, and associated changes in consumer behaviour, and technological innovations.”
The new EU Packaging and Packaging Waste Regulation (PPWR), which sets a range of ambitious environmental targets to be achieved by 2030, has been seen as a key driving force of the market shift for flexible paper and cardboard packaging.
The regulation places a clear focus on sustainability, resource efficiency, and the circular economy, including banning certain single-use formats, making recycled content mandatory in packaging, and using standardised recycling symbols.
However, although paper packaging scores highly in terms of sustainability, consumer image, and recyclability, it also involves major challenges, according to HEIDELBERG.
The company highlights that plastic packaging is currently cheaper than fibre-based solutions in many cases, and consumers are often unwilling to pay the additional cost.
HEIDELBERG also notes that the need to fulfil important barrier functions for food products, beverages, cosmetics, and certain non-food items can also sometimes stretch paper packaging to its technical limits.
In particular, paper does not act as a barrier to moisture, oxygen, or grease. Consequently, either hybrid paper-plastic solutions or functional coatings for monomaterials are required, and such options can result in limited sustainability.
HEIDELBERG summarises that further technological innovations are needed if paper packaging is to be a competitive alternative to plastic in all areas of application.
In response, the manufacturer has announced that it is working with Solenis, a manufacturer of specialty chemicals, to develop a cost-effective process to integrate coatings for fibre-based packaging directly into the existing web flexo printing process.
The new process, which utilises the latest HEIDELBERG Boardmaster high-volume packaging press, will reportedly enable barrier coatings to be applied and combined inline with register accuracy.
David Schmedding, chief technology and sales officer at HEIDELBERG, says: “Cost-effective technology innovations are vital if paper packaging is to replace plastic equivalents on a widespread basis.
“The inline production of coated paper packaging and the cooperation with Solenis to develop innovative varnishes and coatings therefore mean HEIDELBERG is a driver of paperisation. That also makes us a systems integrator in the attractive growth market of mass-producing folding cartons.”
A white paper on the current position of fibre-based solutions in the packaging mix was also released by the manufacturer, which can be downloaded for free from the HEIDELBERG website.
