The Future of Sustainable Flexible Packaging to 2026

Table of Contents Key Facts and Figures

Public pressure and legislative action are creating impetus for change within the entire flexible packaging supply chain, and most notably the development of more sustainable package designs. The term “sustainable” is defined as packaging that is simply “better for the environment” versus alternatives. To avoid argument around such definitions, this report focuses on reviewing and comparing specific strategies being adopted by the flexible packaging supply chain to improve the environmental profile of flexible packaging. This provides the reader with a list of actionable approaches being considered by the whole flexible packaging value chain.

Our exclusive content:

Consideration for the development of more sustainable flexible packaging is the need to adjust strategies for different regions
Package material reductions have been used traditionally to justify the sustainability profile of flexible packaging. Flexible packaging is the lightest of any packaging format, providing unsurpassed performance vs. the amount of package material used
Technical limits for flexible packaging materials are close to being reached, with additional sustainability benefit for further reductions of existing flexible packs showing diminishing returns.

What will you discover?

The recyclable film options that exist today, can meet most needs for product protection, consumer interaction, pack manufacturing, aesthetics, shipment resistance and regulatory requirements, especially certain extremely high barrier requirements that may be challenging
The additional areas of development for flexible packaging which have focused on generally low performance applications including replacement of the PE wraps of fresh produce and bags for loose fruit and vegetables
How many brand owners are seeking to include post-consumer recycled content into their flexible packaging as of 2021, which supports the circular economy by establishing markets for recycled material and closes the circle of recycled material back into fresh packaging.

Who should buy the report?

Materials suppliers
Packaging converters
Brand owners and packaging buyers
Packaging and filling machinery manufacturers
Private and public sector, industry consultants, investors and analysts

The Smithers Methodology

This report is based on extensive primary and secondary research. Primary research consisted of interviews with targeted interviews with packaging material suppliers, converters and experts drawn from key markets. This was supported by secondary research in the form of extensive literature analysis of published data, official government statistics, domestic and international trade organisation data, company websites, industry reports, trade press articles, presentations, and attendance at trade events.

About the author

Dr. Neil Rogers is an award winning package development consultant. He spent 25 years with the Procter & Gamble Company as their global expert in flexible packaging, sustainability, bottle packing & labeling, open innovation and supplier management. He was elected to the board of the CEFLEX Consortium (Circular Economy for Flexible Packaging) and has also worked for Yara International as their only technical packaging specialist for FIBC's & FFS bags. He has extensive experience in R&D, procurement, packing line creation & optimisation, supplier agreements, package specifications, packaging environmental legislation, and patent development with over 25 patent filings.

Name The Future of Sustainable Flexible Packaging to 2026

Date 6/30/2021

Price $6500.00

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Table of Contents

Executive Summary
- Overview
- Sustainable packaging development strategies
  - Reduced flexible packaging weight
  - Recyclable flexible packaging
  - Reusable flexible packaging
  - Recycled content into flexible packaging
  - Sustainably sourced materials for flexible packaging
  - Biodegradable flexible packaging
  - Waste management infrastructure for flexible packaging
    - Developing countries
    - Developed countries
- Material considerations for sustainable flexible packaging

Introduction and Methodology
- Introduction
- Objectives
- Scope
- Methodology
- Definitions
  - Abbreviations
  - Definitions related to legal framework
  - Technical definitions
  - Technical abbreviations

Defining ‘Sustainable Flexible Packaging’
- Introduction
- Flexible packaging
  - Definition
  - Examples of flexible packaging forms and types
  - Materials and structures used in flexible packaging
    - Materials
    - Structures
- Sustainable packaging definition
- Factors driving more sustainable packaging
  - Public pressure
  - Legislation
    - Impact of EU legislative on package design
    - Impact of EU legislative on package taxation & EPR
    - Impact of EU legislative on waste management
- Sustainable packaging development strategies
  - Definitions and global applicability
  - Reduce
  - ‘Recyclable’
  - Reuse
  - Recycled content
  - Sustainably sourced materials
  - Biodegradability
  - Waste management infrastructure development
- Flexible packaging performance needs
  - Product protection
  - Consumer interaction
    - Easy opening
    - Reclosure
    - Product dispensing
    - Microwaveable / oven ready
    - Child resistance (CR)
  - Package manufacture and format
  - Packing process
    - Material transport, forming and cutting
    - Sealing
    - Retort-ability
    - Modified atmosphere packing (MAP)
  - Shipment
  - Aesthetics
  - Financials
  - Regulatory needs
  - Sustainability

Reduced/light-weighted flexible packaging
- Introduction
- Downgauging
- Rigid to flexible conversion
- Refill packaging
- Product concentration
- Conclusions

‘Recyclable’ flexible packaging
- Introduction
- Definition of ‘recyclable’ packaging
- Recyclable flexible packaging: Current effort
- Recyclable flexible packaging: Performance challenges
- Plastic to paper conversion
- Conclusions

Reusable flexible packaging
- Introduction
- In-store refill
  - Rigid packaging
  - Flexible packaging
- At-home refill
- Conclusions

Recycled content into flexible packaging
- Introduction
- Sources of recycled material for flexible packaging
  - LDPE
  - HDPE
  - PET
  - PP
  - Nylon
- Conclusions

Sustainability sourced materials for flexible packaging
- Introduction
- Sustainably sourced plastic
- Paper
- Conclusions

Biodegradable flexible packaging
- Introduction
- Legislative outlook
- Plastics for biodegradable flexible packaging
- Paper
- Conclusions

Waste management infrastructure developments for flexible packaging
- Introduction
- Developing countries
- Developed countries
  - Improved collection of flexible packaging waste
  - Improved waste management and material recovery
- Other developments for flexible packaging
  - Retain™
  - Enval
  - Cadel de-inking
  - Erema de-odorization
  - Saperatac layer separation
- Consortium activity
- Conclusions

Materials for sustainable flexible packaging
- Introduction
- LDPE
  - Weight reductions
  - Recyclability
  - Recycled content
  - Sustainable sourcing
  - Waste management infrastructure
- PP
  - Weight reductions
  - Recyclability
  - Recycled content
  - Sustainable sourcing
  - Waste management infrastructure
- PET
  - Weight reductions
  - Recyclability
  - Recycled content
  - Sustainable sourcing
  - Waste management infrastructure
- Paper
  - Recyclability
  - Sustainable sourcing
  - Biodegradable
- Alu
  - Recyclability
  - Waste management
- Nylon
  - Recyclability
  - Waste management
- EVOH
  - Weight reductions and recyclability
- PVdC
  - Weight reductions and recyclability
- PVC
- Biodegradable plastics
  - Biodegradability vs. circularity

List of Figures

FIGURE 2.1. PE based mono-film for paper-based products
FIGURE 2.2. Medium barrier laminate for stand-up pouches
FIGURE 2.3. High barrier laminate for wet pet-food pouches
FIGURE 2.4. High barrier thermoformable film for vacuum packs
FIGURE 2.5. The top 10 country list of plastic pollution by weight plus other selected countries for both mismanaged waste and marine litter
FIGURE 2.6. Percentage of plastic waste that is mismanaged per country in 2010.
FIGURE 2.7. Sources of plastic marine litter
FIGURE 2.8. An overview of EU climate regulations from 2015 to 2025, with implications for package design
FIGURE 2.9. The EU Waste Hierarchy, and details of liner vs. circular economy approach
FIGURE 2.10. A pictorial representation of future EPR plans based on layers of different EPR charges
FIGURE 3.1 – The EU’s Waste Hierarchy and how the linear and circular economy fit into this hirearchy
FIGURE 4.1 – Tesco’s preferred packaging material list
FIGURE 4.1. A technical assessment of the suitability of various commercially available recyclable films options to replace a PET/LDPE laminate
FIGURE 4.2. A technical assessment of the suitability of various commercially available recyclable films options to replace a PET/Alu/LDPE laminate
FIGURE 6.1. The composition of the UK flexible packaging household waste stream in 2016
FIGURE 6.2. A breakdown of the main flexible packaging formats in the UK household waste stream in 2016
FIGURE 8.1. An overview of global production capacity of bioplastics
FIGURE 8.2. A technical assessment of the suitability of various commercially available biodegradable films options to replace a PET/LDPE laminate
FIGURE 8.3. A technical assessment of the suitability of various commercially available recyclable films options to replace a PET/Alu/LDPE laminate
FIGURE 9.1. The top 10 country list of plastic pollution by weight plus other selected countries for both mismanaged waste and marine litter
FIGURE 10.1. The composition of the UK flexible packaging household waste stream in 2016
FIGURE 10.2. A breakdown of the main flexible packaging formats in the UK household waste stream in 2016
FIGURE 10.3. A technical assessment of the suitability of various commercially available biodegradable films options to replace a PET/LDPE laminate
FIGURE 10.4. A technical assessment of the suitability of various commercially available recyclable films options to replace a PET/Alu/LDPE laminate

List of Tables

TABLE 0.1. The 7 main strategies being explored by the packaging supply chain to improve the sustainability of flexible packaging
TABLE 0.2. How the 7 strategies for sustainable package development differ in different parts of the world
TABLE 0.3. The 3 main materials families being considered for recyclable flexible packaging
TABLE 0.4. Typical materials used in flexible packaging categorised by their main property benefits and recyclablility profiles as of 2021
TABLE 0.5. The sustainability profile of some of the main materials used in flexible packaging in 2021
TABLE 1.1. Abbreviations relating to legal framework
TABLE 1.2. Definitions related to legal framework
TABLE 1.3. Technical definitions
TABLE 1.4. Technical abbreviations
TABLE 2.1. Typical flexible packaging forms
TABLE 2.2. Typical materials used in flexible packaging categorised by their main property benefits
TABLE 2.3. Summary of the main implications of EU packaging legislation on future package design
TABLE 2.4. Summary of the main implications of EU packaging legislation on future EPR and taxation
TABLE 2.5. Summary of the main implications of EU packaging legislation on future package waste management
TABLE 2.6. Updated packaging recycling targets to 2030 arising from the PPWD
TABLE 2.7. The 7 main strategies being explored by the packaging supply chain to improve the sustainability of flexible packaging
TABLE 2.8. How the 7 strategies for sustainable package development differ in different parts of the world
TABLE 2.9. Overview of the main package performance criteria for flexible packaging
TABLE 2.10. Typical published oxygen and water vapour transmission values for a range of different film layers used in flexible packaging
TABLE 2.11. Properties of flexible packaging to enable correct pack formation on packing line
TABLE 2.12. Properties of flexible packaging that enable reliable sealing on packing lines
TABLE 2.13. Typical factors influencing the total cost of sustainable flexible packaging vs. current package designs.
TABLE 4.1 – Summary of recyclability guidelines from different packaging organisations
TABLE 4.2. The 3 main materials families being considered for recyclable flexible packaging
TABLE 4.3. Typical materials used in flexible packaging categorised by their main property benefits and recyclablility profiles as of 2021
TABLE 4.4. The challenges of recyclable flexible packaging structures to match current performance needs of flexible packaging
TABLE 4.5. The challenges of paper-based flexible packaging to meet current performance needs of flexible packaging
TABLE 4.6– Recent development to improve the performance of paper packaging to enable plastic packaging replacement
TABLE 6.1. Examples of recyclers and suppliers of LDPE recyclate
TABLE 6.2. Effort at resin suppliers to supply both recyclate-virgin blends of LDPE and virgin LDPE made from chemically recycled plastic waste
TABLE 7.1. The main policy areas and scope of the EU Green Deal
TABLE 7.2. Resin supplier activity to supply sustainably sourced polyolefins
TABLE 7.3. Internationally recognised certification processes for sustainable sourcing of paper based packaging
TABLE 8.1. Overview of the biodegradable plastics used in flexible packaging
TABLE 8.2– Recent development to improve the performance of paper packaging to enable plastic packaging replacement
TABLE 9.1 – Details of consortia activity for sustainable packaging
TABLE 10.1. Typical materials used in flexible packaging categorised by their main property benefits
TABLE 10.2. The sustainability profile of some of the main materials used in flexible packaging in 2021
TABLE 10.3. Sustainability of LDPE in flexible packaging in 2021 to 2026
TABLE 10.4. Examples of recyclers and suppliers of LDPE recyclate
TABLE 10.5. Effort at resin suppliers to supply both recyclate-virgin blends of LDPE and virgin LDPE made from chemically recycled plastic waste
TABLE 10.6. Sustainability of polypropylene in flexible packaging from 2021 to 2026
TABLE 10.7. Sustainability of PET in flexible packaging from 2021 to 2026
TABLE 10.8. Sustainability of paper substrates in flexible packaging from 2021 to 2026
TABLE 10.9. The challenges of paper-based flexible packaging to meet current performance needs of flexible packaging
TABLE 10.10– Recent development to improve the performance of paper packaging to enable plastic packaging replacement
TABLE 10.11. Internationally recognised certification processes for sustainable sourcing of paper based packaging
TABLE 10.12. Sustainability of aluminium in flexible packaging from 2021 to 2026
TABLE 10.13. Sustainability of nylon in flexible packaging from 2021 to 2026
TABLE 10.14. Sustainability of EVOH in flexible packaging from 2021 to 2026
TABLE 10.15. Sustainability of PVdC in flexible packaging from 2021 to 2026
TABLE 10.16. Sustainability of PVC-based in flexible packaging from 2021 to 2026
TABLE 10.17. Countries where bans of PVC-based packaging are in place as of 2021
TABLE 10.18. Overview of the biodegradable plastics used in flexible packaging
TABLE 10.19. Sustainability of biodegradable plastics in flexible packaging from 2021 to 2026