Lightweighting and Thinner Films Accelerate: A Low-Carbon Shift in Flexible Packaging Structures

Among packaging trends, flexible structures show remarkable staying power because their evolution tends to unfold slowly. The following formats have already changed or are changing now.

Cartons now offer more opening options and simpler handling. Small fittings are used for opening and closing; zippers on some stand-up pouches, for example, allow consumers to twist or reseal rather than tear the pack. Machinery has advanced considerably too: with more functions built in, integrated filling-to-packaging service can be delivered in the shortest possible time.

Clear high-barrier films. The barrier performance of next-generation transparent films and coatings is moving closer to that of metal foil and metallized films. This creates a display advantage, letting shoppers see highly appetizing food directly. Such structures are also convenient for microwave heating.

The preferred packaging for new products. After years of development, flexible packaging is widely expected to cover all product categories. Tuna and pet food are typical examples: after decades of canning, retort pouches have become mainstream. More recently, glass jars for baby food have also been replaced by retort pouches.

One step ahead. Packaging ketchup in larger, more flexible stand-up pouches is no longer a novelty, so pouch formats for other condiments are not far behind. Successful test marketing in Europe, Asia and Latin America has proved this to be a marvel. New packaging for shampoo and laundry detergent arrived when the time was right, and the same applies to canned fruit.

Global breakfast cereal flexible packaging advances slowly. In both low-end and high-end markets, flexible packaging has entered the view of cereal manufacturers. Experts acknowledge, however, that switching to flexible packaging within a short period would require very high investment in packaging machinery. In addition, although renewable resources offer many advantages, it is unlikely that flexible packaging materials can be directly replaced by recycled paperboard. The main reason is that flexible packaging does not mean consumers nationwide will accept it, especially Americans.

More layers in the coextrusion stage. At first, this may sound incorrect, but in practice adding layers to a flexible packaging structure can save cost and improve performance. How? It demands more precise layer control. 3-5 layer film coextrusion lines are limited by extruder size and die design. 7-9 layer coextrusion lines can produce better-performing, thicker flexible packaging materials at lower cost because no structural redesign is needed. One approach uses cheaper resin as the bulking layer. Another separates the moisture barrier into two thinner layers, with one held in reserve against pinholes connecting with other layers. This method also increases the number of moisture-barrier surfaces, further reducing permeation. Various technologies can divide moisture-barrier material into many layers, and data shows a linear improvement in moisture resistance.

The right flexible packaging shape. Contemporary packaging styles can create more shapes than before. Consumer packaged goods companies want new formats because shelf standout is critical. Stand-up pouches with nearly two curved spaces removed are now out of fashion, even though machines from outside equipment suppliers are almost all producing this conical stand-up pouch. At the same time, as stand-up pouch shapes become more complex, controlling design waste is a challenge that must be addressed.

The broad impact of pouches. Because pouch structures can be customized to requirements, many new physical product forms have appeared: liquid, viscous, powdered, granular and particulate. This has led to overlaps between products, including food and beverages, cosmetics, healthcare, pet food, automotive, pharmaceuticals and agricultural products. Flexible packaging fill speeds have not yet matched common carton speeds, but the gap is narrowing, especially in dry products.

The low-carbon and environmental protection storm has reached the packaging industry. In recent years, the global wave of low-carbon and environmental protection has entered packaging and introduced the concept of low-carbon packaging. Its main elements include lightweight packaging, clean production, green products, energy saving and emission reduction, and replacing wood with paper; replacing wood with paper is the core. Waste paper recycling not only cuts wood use, reduces tree felling and protects the ecological environment, but also saves energy, water and emissions. In product development, companies must fully consider social responsibility and keep green packaging central: the materials developed should be recyclable, regenerable or degradable, and should not affect people or the environment throughout the product life cycle. While packaging functionality is met, waste generation should be minimized as much as possible, steering packaging films and materials toward lightweight and thinner development. At present, regulations banning EPS foamed plastic cushioning have already forced Chinese enterprises to eliminate foamed plastic in export packaging for home appliances and switch to eco-friendly cushioning such as honeycomb paperboard. Honeycomb paperboard is a new sandwich-structure, eco-friendly and energy-saving material made by combining high-strength honeycomb paper cores with various high-strength kraft papers; it offers low cost, low material use, sound absorption and heat insulation, high strength and good impact resistance. Honeycomb paperboard is made entirely from recyclable and renewable paper, can replace wood, and can be fully recycled and reused after use.

At present, China's packaging machinery products have few varieties, low technical levels and poor reliability, and no advantage in the international market; more than 80% of processing and packaging equipment is imported. With tasks such as developing deep processing of agricultural products, building a conservation-minded society and developing a circular economy, the market for packaging machinery products is very broad. If packaging machinery enterprises accelerate technological innovation and adapt to market demand, they can gain considerable profits.

This article is reprinted from China Packaging Network (news.pack.cn). Original link: http://news.pack.cn/show-373071.html. Copyright belongs to the original author; it is provided for industry exchange and learning only.