With the increase in demand for paper-based packaging showing no signs of slowing down, what are some of the latest materials in this sector to help your clients’ products stand out on the shelves?
There has been no escaping the widespread shift to paper-based packaging. Whether this is popping open a can of Pringles without their famous metal bottom or opening a multi-pack of tissues in preparation for the hay fever season, more brands and retailers are turning their attention to what is possible with paper-based solutions.
With this has come a noticeable increase in demand for printers offering such a service. As we all know, packaging has been a key growth area for a number of years now. Still, with the use of paper-based products on a continuous rise due to the fact that this offers a much more sustainable option, demand is higher than ever. Both print service providers (PSPs) and suppliers are having to respond.
Here, we speak with several companies about their latest packaging materials and how these solutions can help PSPs capitalise on what has been one of the stand-out industry trends in recent years.
First up is Flint Group, which, in its own words, is dedicated to serving the global flexible packaging, paper and board, narrow web, and publication markets. Kari Raassina, senior director of product management Europe at Flint, says sustainability continues to dominate conversations in the paper packaging sector, with consumer demand and evolving regulations combining to encourage converters towards more eco-conscious technologies.
“Businesses are increasingly expected to show that they care about this topic and actively demonstrate how they contribute to it,” Raassina says, adding: “Inks and coatings designed to minimise impact on the planet, in conjunction with more sustainable substrate choices, present the best route forward for printers to demonstrate concrete action in this area.
“Most brands are aware of the environmental benefits of using renewable, recyclable, and compostable substrate materials. However, the role that ink and coating technology can play in supporting sustainability initiatives is too often overlooked.
“As high-volume consumables, inks, and coatings can significantly contribute to a business’ environmental footprint. This means that prioritising low-carbon, VOC-free, and ink technology based on bio-renewable content and recycled raw materials can pay dividends.”
Raassina goes on to say that while sustainable inks and coatings are one thing, they must also provide high-quality print performance. Raassina advises accurate colour reproduction and on-press stability are important considerations that must be made when selecting inks, and with the growing demand for short-run, varied jobs, high substrate compatibility can unlock untold benefits for flexibility and efficiency.
High-volume consumables, inks, and coatings can significantly contribute to a business’ environmental footprint
“Finding ink technology that balances performance with sustainability is key to success,” Raassina says, adding: “Creating more sustainable paper and board packaging involves more than just the material it is made from. Choosing inks and coatings designed to minimise environmental impact is crucial for achieving sustainability goals. Innovations in ink technology, such as those by Flint Group, make these goals attainable.”
With this, Raassina draws attention to some of the options available from Flint. These include TerraCode Bio, its most recent product launch for the paper and board sector. Flint says this extended range is designed to maintain the print and resistance properties of conventional ink systems while maximising the use of renewable content.
The series includes a selection of OK Compost-certified options to support paper packaging markets, including standard and technical extenders, and coatings for corrugated for post- and pre-print, which can be used alongside Flint Group’s HexaCode and OctaCode bases.
“Products in the TerraCode Bio range replace traditional extender components with high-quality bio-based alternatives,” Raassina explains, continuing: “These formulations feature up to 90% bio-renewable content, while still providing outstanding print quality and on-press stability, helping converters to reduce their carbon emissions produced by Flint Group’s products by up to 40%.
“TerraCode Bio also maintains the resistance properties of conventional ink systems – a significant achievement given the difficulty of maintaining performance characteristics while maximising bio-renewable content.”
Raassina goes as far as to say that the quality offered by TerraCode Bio is comparable or superior to existing synthetic technology, and the range can be used alongside existing base systems. This, he continues, facilitates a smooth transition from previous extender ranges, reducing downtime and disruption.
“Offering excellent coverage, tonal values, and trap quality, with no compromise on the environment, TerraCode Bio is the ideal solution for environmentally conscious printers looking to create high volume uncoated work and high-quality coated designs,” he says.
Up next is Encore Machinery, which specialises in solutions for paper and board conversion machinery. Managing director Paul Davidson says sustainability is only one trend that the company has picked up in recent months. He explains that the shift towards environmentally friendly materials is more prominent than ever, with consumers and businesses demanding packaging solutions that minimise environmental impact, such as recyclable, biodegradable, and compostable options.
Aside from this, Davidson highlights other key trends that PSPs in this sector should look out for. He explains: “Firstly, smart packaging; integrating technology into packaging, including QR codes, NFC tags, and IoT sensors, is revolutionising how products are tracked, authenticated, and interacted with by consumers.
“Then there is personalisation and the fact that fully customised bespoke packaging catering to individual customer preferences or specific market segments is gaining traction. Advances in digital printing technology and short-run, quick-make-ready finishing solutions are allowing this trend to develop.
“Also consider minimalist design and the growing preference for clean, simple packaging designs that focus on essential information and aesthetics and reduce unnecessary elements.
“In addition, think about e-commerce optimisation. With the rise of online shopping, packaging that ensures product safety during transit while providing a pleasant unboxing experience for the consumer is becoming increasingly important.”
So, how can PSPs ensure they are addressing these trends in the most effective way? Once again starting with sustainability, Davidson says that to meet the ever-increasing consumer demand for eco-friendly options, PSPs should be opting for materials that are recyclable, biodegradable, or sourced from renewable resources.
Casting the net wider, Davidson recommends PSPs prioritise other factors when selecting packaging materials. These include durability, in that materials should offer robust protection to ensure products arrive intact and undamaged, as well as regulatory compliance where it’s recommended that PSPs verify materials used to meet industry standards and regulations, particularly for sensitive sectors like food and pharmaceuticals.
On the back of this, Davidson says print quality is of paramount importance and that to enhance visual appeal, PSPs need to ensure materials support high-resolution print, vibrant colours, sharp images, and the ability to allow further product embellishments with good fibre content to enable a perfect finished product. In addition, linking in with this, he says PSPs should balance quality with affordability to provide cost-effective solutions without compromising a machine’s performance.
So, how can Encore help? Davidson says the company has seen its customers using several innovative and popular packaging products on various machines available from the manufacturer.
These include ‘Eco-Pack’ products which are crafted from 100% recycled materials and require being fully biodegradable, catering for industries, including food, cosmetics, and electronics. Then there is the issue of ‘Smart Park’ solutions, which feature NFC and QR code technology, offering interactive customer experiences such as product information, promotional content, and authenticity verification.
In addition to this, there is the option for ‘Custom Printed Boxes’, which use advanced digital printing techniques, can be personalised for branding, special events, or limited editions and offer vibrant and detailed designs with innovative product design. Finally, Encore users can create ‘E-commerce Shield’ products, which Davidson says are designed for online retailers and provide superior protection during shipping while enhancing a customer’s unboxing experience.
“We offer innovative solutions to clients from some market-leading manufacturers to meet their evolving needs while promoting environmental responsibility,” Davidson adds.
Also commenting here is Julia O’Loughlin, group marketing manager at Parkside Flexibles, which specialises in packaging solutions. O’Loughlin says sustainability is the longest, most significant market trend that has impacted every industry, especially the packaging sector. She adds that while it is not a new trend, it is continually evolving, and the pace of change is definitely picking up.
“In recent years, major legislation specifically targeting packaging, such as the plastic packaging tax, has been put in place, and further measures like Extended Producer Responsibility are planned as the industry is pushed towards more easily recyclable products,” O’Loughlin explains.
“It is not just legislation that is driving these changes, as consumer preferences and brand goals are also a factor. Many brands and retailers have set targets to reduce or eliminate plastic packaging by 2025 or 2030, as they look to respond to consumers who want businesses to provide more sustainable packaging options.”
It is not just legislation that is driving these changes, as consumer preferences and brand goals are also a factor
Another trend O’Loughlin says is affecting the packaging industry is the rising cost of materials and energy. O’Loughlin says Parkside tries hard to mitigate cost inflation where possible for customers. This, she adds, might mean looking at cost-effective alternative materials, new structural designs, and streamlined production processes to help keep costs low without compromising on pack performance.
“Quality versus cost has always been a critical balancing act to pull off. We work every day to balance increasing costs with our strict quality standards,” O’Loughlin says, adding: “Secure supply chains are also important.
“There have been quite a few issues recently that have seriously affected supply chains across the world, such as the Red Sea attacks and the continuing war in Ukraine. We have a solid, diverse network of suppliers that we work closely with and have therefore fortunately seen minimal impact.”
As for what is new from Parkside, the company recently launched the Recoflex range of barrier papers with varying properties. These materials, O’Loughlin says, are suitable for various end applications, with products ranging from translucent paper for salad bags to freezer-grade paper that is robust enough for the entire cold chain.
“The freezer-grade paper material was first used in an award-winning packaging innovation last year, where we used it to create a first-to-market fully freezer-proof, 100% recyclable paper pouch for frozen seafood,” O’Loughlin explains, continuing: “The launch of Recoflex builds on this success by adding new grades of material for a variety of exciting new applications including a high barrier paper, a metallised paper, and a flow wrap material – all of which are 100% recyclable.”
This also follows last year’s launch of Recoflex monopolymer laminates, a range of PE and PP recyclable substrates for a variety of product applications. In addition, O’Loughlin says the compostable portfolio at Parkside remains popular, and after over a decade in development is the most refined and accredited on the market.
“Compostables are popular with small- and medium-sized brands that pride themselves on a more ethical ethos,” O’Loughlin concludes.
There are several major trends that PSPs need to be aware of and respond to if they are to grow and succeed within the packaging market. Ensure you are using the right materials from trusted suppliers to achieve the highest quality output.
