Kuraray: Sustainable packaging made of paper and innovative polymers

Author Dr. Bettina Plaumann

Sustainability is the big trend in the packaging market. The focus is on using renewable raw materials, cutting CO2 emissions and developing monomaterial-based packaging. Recyclability and circularity are major challenges. Therefore, the repulpability, recyclability, compostability and biodegradability of packaging are becoming more important.

More sustainability and less use of resources are big challenges for society – worldwide. These days, consumers consciously give preference to sustainable packaging that can be recycled. Big brands and retailers in the food industry such as Danone, Mondelez, Nestlé and Unilever along with Sainsbury’s and Walmart have already issued voluntary commitments on sustainability – the sector has set circular packaging solutions as its goal.

Innovative materials

Innovation is key to achieving these objectives. Kuraray’s products and know-how make an essential contribution to the development of innovative packaging. Why continue to package coffee beans in aluminium pouches when paper pouches with a PLANTIC™ layer also provide an excellent barrier to oxygen? PLANTIC™ is a biopolymer derived from starch. Moreover, packaging with water-dispersible, biodegradable PLANTIC™ ensures that paper fibres can be repulped without difficulty.

Another example is EVAL™ – our ethylene vinyl alcohol (EVOH) copolymer. Inserting a barrier layer of innovative EVAL™ SC resin between two layers of polyethylene produces a shrink bag for fresh red meat that is both super transparent and recyclable. The thin layer of EVAL™ EVOH produces particularly light and resource-saving packaging.

Another highlight: Kuraray is the first EVOH producer to offer biocircular EVOH with ISCC PLUS certification. Certification is based on the mass-balance approach and documents the fact that the ethylene monomer in EVAL™ is produced from renewable resources.

PFAS are under scrutiny, and the European Packaging and Packaging Waste Regulation (PPWR) now even bans these substances in food packaging above specific thresholds. Brand owners are therefore on the lookout for new, sustainable solutions. The great news from Kuraray is that PFAS can easily be replaced by EXCEVAL™ in paper-based packaging for dry food. Unlike conventional fluoropolymers, EXCEVAL™ is water-soluble, so this type of packaging can easily be recycled in paper mills. 

Just as good – but more sustainable

As a brand owner, you are under pressure to come up with new and more sustainable packaging solutions as quickly as possible, without any reduction in functionality. Here is an example: If you just want to reduce the film layers in multilayer packaging you could simply reduce the weight. However, using thinner layers might mean the packaging no longer has the required barrier properties. What you need are innovative materials.

Kuraray’s products and sector insight can give you completely new options. In our case studies, which you can download below, you can read more about new packaging concepts that successfully combine sustainability with functionality.

We know that every customer has different needs. Your packaging requirements are very specific. And so are the innovative solutions we develop together with you. We’re convinced we can only design the future by working together. That’s what our Innovation Networking Center (INC) is all about. Here, we network our expert knowledge on a global scale within the company and beyond. By networking, sharing knowledge and working together at the INC, we can create value and come up with innovations – with and for our customers.

A global perspective on the sustainability megatrend

Sustainability is the megatrend in the packaging industry. However, it also results in regional differences in the demands made by consumers, legislators and regulators. In recent years, governments in many countries have responded to consumer concerns by endeavouring to reduce packaging waste and improve waste management systems. Unfortunately, the regulations vary greatly from one country to another. At present, there is no global harmonization. Moreover, many countries do not have the necessary recycling infrastructure and processes.

As a brand owner, you may have to adopt new material concepts to make sure your packaging can be recycled locally. For example, repulpable packaging made primarily of paper with only a thin barrier layer can be a worthwhile goal. Ideally, a suitable, water-soluble film should improve the paper fibre yield in the repulping process. Alternatively, you could opt for a monomaterial composite with a very thin yet highly functional barrier layer that does not interfere with common recycling processes. Depending on the applicable regional requirements, such packaging can be recycled as a monomaterial. There are many ways to make your packaging much more sustainable and adapt it to local requirements.

Barrier packaging materials

A barrier is anything that blocks passage, i.e. what leaves or enters the package. Barrier materials are impermeable structures that prevent oxygen and gases flowing in or out, keeping flavours and aromas inside, and contaminants and potential pollutants out. In this way, barriers extend the shelf life of valuable (food) products and help prevent them spoiling and turning into waste. 

Barrier packaging is most commonly used to protect food but there are many other goods that are also susceptible to contamination. These include detergents, personal care products such as lotions and shampoos, and many more.  

Kuraray offers barrier materials for different processing technologies: from (co-)extrusion, (co-)injection and lamination to coating with films and aqueous solutions. Our portfolio includes bio-based, biodegradable and compostable products, as well as sealing films. 

Paper packaging with a barrier layer

Paper packaging is becoming increasingly popular. Not least because these days many consumers routinely recycle paper. As a result, paper has a better image than plastics. Consumers regard paper packaging as more sustainable – and better quality. By using paper packaging, brand owners can show that they take quality and sustainability seriously. However, 100% paper packaging is not generally suitable for food. A suitable barrier layer is needed to resist moisture, oxygen and grease and seal in aroma.

That’s where Kuraray’s innovative solutions come in. Our products help you design customized paper packaging which meets all functional requirements – including for food. In addition, our experts will help you develop paper packaging concepts based on our barrier materials that meet repulpability requirements.

Sustainable plastic packaging

Plastic packaging deserves special attention in the quest to improve the sustainability of packaging. Reducing the amount of material, using plastics made from renewable resources and designing recyclable packaging are important to enhance the sustainability of plastic packaging. Products from Kuraray open up a wide range of possibilities.

We offer materials with a variety of benefits: bio-based, recyclable, water-soluble, fully biodegradable or compostable (industrial or home composting). In many cases, our products can be used for very thin barrier layers. These can greatly reduce the amount of material used in your packaging and even ensure that packaging can be recycled as a monomaterial.

As you can see: plastic packaging has enormous innovative potential. Our products and expertise can help you utilize that potential.