From Plastics To Plants: The Evolution of Packaging

It’s hard to imagine our world without packaging. It plays a crucial role in our daily lives by not only allowing companies to safely transport and protect goods but also by extending the shelf life of products. Modern day packaging is more than just a protective shell, it contributes to the overall impression and branding of a product and is an integral part of product presentation, customer satisfaction and experience.

Initially, mostly due to the lack of man-made materials, packaging was sustainable by default, utilizing materials such as cartons, glass, reusable containers, and metals. These materials were chosen for their durability and ability to protect products effectively. However, with the development of various plastics, the packaging industry underwent a significant transformation. Plastics offered new possibilities with their versatility, lightweight nature and low production costs, becoming a dominant material in the market. 

So what materials are on the market today and what’s the story behind them? 

Paper

The invention of the commercial paper bag in Bristol, England, in 1844 marked the beginning of a new era in packaging. Francis Wolle’s invention of the bag-making machine in 1852 in the United States further revolutionized the industry. His machine automated the production of paper bags, making them more accessible and affordable for widespread use. 

Paper and paperboard packaging saw a steady rise in popularity well into the 20th century. However, with the invention of plastics as a major packaging material in the late 1970s and early 1980s, paper-based packaging lost its popularity. In recent years this trend has risen again as designers and manufacturers respond to growing environmental concerns, leading to a growing popularity of paper and paperboard packaging.

Today, paper remains a cornerstone of flexible packaging due to its versatility, sustainability, and cost-effectiveness. It can be made from recycled materials and organic waste. Papair (Germany) makes bubble wrap from recycled paper and Eco:fibr (Germany) transforms pineapple plant residues into eco-friendly pulp. 

The only downside of paper production remains the usage of various chemicals for bleaching, coloring, creation of the smoother fibers and others. And such materials as phthalates, diisopropylnaphtha-lenes (DIPNs) and benzophenone can even migrate to dry foods. 

Glass

While other packaging materials like metals and plastics gained popularity in the 1970s, glass packaging was often reserved for high-value products, like cosmetics, oils, perfumes due to its premium feel and excellent preservation qualities. Today glass is commonly used in packaging beverages like wine, spirits, and craft beers, as well as in preserving food items such as sauces, jams, and pickles. Additionally, glass is favored in the pharmaceutical industry for storing medications and in the cosmetic industry for perfumes and skincare products. The durability, inertness, and recyclability of glass make it a versatile and sustainable choice for use in various industries.

But due to its fragile nature, in many cases glass needs its own protective shield. For transportation, cushioning, thermal insulation glass needs a secondary packaging that has these properties. Polystyrene is now the material of choice for many companies, but there are other fully sustainable and biodegradable options on the market, like the packaging that we produce at S.Lab. 

Plastics

Plastic is the youngest packaging material compared to others like glass, metal, and paper. While its discovery dates back to the 19th century, the widespread use of plastic for packaging primarily took off in the mid-20th century.

By the late 20th century, plastic had firmly established itself as a cornerstone of the packaging industry. It became the material of choice for packing various products, actually, almost every single product – from food and beverages to electronics and household goods. The development of different types of plastics, such as PET (polyethylene terephthalate) for bottles, HDPE (high-density polyethylene) for containers, bubble wrap for fragile objects, cellophane further expanded the plastics domination on the market. And after a couple of decades the situation with plastic pollution became catastrophical. 

New era of materials

Today, packaging innovators are constantly developing new methods and materials to minimize the environmental impact of the traditional packaging industry. The rise of adoption of circular economy principles is a crucial trend influencing the packaging industry. Companies are increasingly implementing sustainable practices that allow the reuse and recycle of materials, thereby creating a closed-loop system. This approach not only conserves limited resources but also reduces environmental pollution. For example, some businesses are implementing packaging as a service models and take-back programs where consumers can return used packaging for recycling or repurposing, some utilize new materials instead of plastics and polystyrene, and some make their packaging refillable.

Both industry experts and independent startups are exploring new ways to enhance recyclability and reduce overall material usage. This includes designing packaging that is easier to disassemble and recycle, using fewer resources to achieve the same protective qualities, and incorporating recycled materials into new packaging products. Substitutes such as starch, cellulose, mycelium, biopolymers, as well as materials from sugarcane, coconut, hemp, and cornstarch, are dominating in replacing conventional plastics.

Mycelium

Mycelium, or network of mushroom roots, is one of those new promising materials due to its natural properties. It acts like a glue, due to its binding properties, is completely biodegradable, breaking down naturally in the environment without leaving harmful residues, unlike conventional plastics, which can take hundreds of years to decompose. Mycelium is a renewable resource and can be grown in a lab, it can be formed into various shapes, making it suitable for a wide range of packaging applications, and despite its organic origins, mycelium is surprisingly strong and durable, providing effective protection for packaged goods.

As for the environmental benefits, mycelium has it all. Such packaging requires less energy to produce compared to traditional plastic and Styrofoam, resulting in a lower carbon footprint, and utilizing agricultural waste as a raw material it helps divert this waste from landfills and reduces the overall waste generated by packaging. In terms of durability, mycelium-based packaging has all the same properties as polystyrene packaging — it is waterproof, fire resistant, humidity resistant and thermally insulating. 

The global mushroom packaging market is estimated to grow from USD 58.58 million in 2022 to reach an estimated USD 122.43 million by 2032, registered at 7.7% CAGR between 2023 and 2032 with Europe to drive 40% of market growth in forecast period. 

There are a bunch of notable companies on the market who make this type of packaging: S.Lab (Spain), Ecovative (US), Magical Mushroom Company (UK), Grown.bio (Netherlands) and many others. S.Lab even overcame the main problem of all alternative packaging producers — scaling. They developed their own technology that allows them to produce mycelium packaging on an industrial scale. Taking into account that global production capacity of polystyrene amounted to 15.44 million metric tons in 2022 and continues to grow, the world will need a lot of alternative packaging to replace such tremendous amounts of foamed plastic.

Algae

Among innovative alternatives, algae-based packaging is emerging as a promising player. One of the most significant advantages of algae packaging is, of course, its biodegradability. Unlike traditional plastics, algae-based materials break down naturally and harmlessly. Algae are highly efficient at capturing carbon dioxide during their growth. This means that the cultivation of algae for packaging not only reduces CO2 levels in the atmosphere but also helps combat climate change. The carbon-neutral or even carbon-negative footprint of algae packaging makes it an environmentally friendly choice.

Algae packaging is used to create biodegradable food containers, wrappers, and bottles. These products are not only eco-friendly but also safe for direct contact with food. They provide a sustainable alternative to single-use plastics in the food industry such as straws, cutlery, and shopping bags. 

Several innovative companies are at the forefront of developing and commercializing algae-based packaging solutions. Some of the key players include Algopack (France) — a pioneer in algae-based bioplastics, Loliware (US), Evoware (Indonesia) and many others.

Recyclable materials

Another step towards a circular economy is the use of recycled materials. This move is driven by the need to reduce the demand for raw materials and mitigate the environmental impact associated with packaging production. Many companies are opting for packaging made from recycled paper and cardboard. These materials are ideal for creating boxes, cartons, and other packaging products, providing a sustainable alternative to virgin paper and cardboard. Brands like Apple and Amazon have incorporated recycled paper into their packaging to reduce their environmental impact.

Recycled plastics are being used to produce a wide range of packaging items, including bottles, containers, and wrapping materials. Industry leaders like Coca-Cola and Unilever are using recycled PET (polyethylene terephthalate) for their beverage bottles, demonstrating a commitment to sustainable practices.

Glass can be recycled indefinitely without losing quality or purity. Companies in the beverage and cosmetics industries are increasingly using recycled glass for their products, reducing the need for new glass production and the associated environmental impacts. 

While the market adoption of recycled materials and alternative packaging solutions is promising, there still are challenges to overcome. We need to address all the aspects of the supply chain, such as product design, transportation and disposal. Scalability of production lines and technologies, consistent supply of high-quality recycled materials, production costs, and changing consumer perceptions are critical for the industry. However, technological advancements, new innovations and growing consumer awareness about environmental issues are driving positive change. The future of packaging is set to become increasingly sustainable.