Sustainable plastics for food packaging

The plastic films used in the food industry continue to predominantly be made of conventional plastics such as polyethylene (PE) and polypropylene (PP). In 2022, packaging accounted for around 40 percent of total plastic consumption worldwide, with food packaging making up a significant share. One small bright spot is that in Europe, there is a growing trend towards using sustainable materials.

One of the global players in the development of innovative materials is Taghleef Industries, an interpack exhibitor and member of the SAVE FOOD initiative. The Dubai-headquartered company operates globally and specialises in the production of PP-based, bio-based and bio-degradable films for flexible packaging, labels, graphical applications, decorative surfaces and industrial applications.

Allegra Muscatello, product manager at Taghleef Industries, describes the complexities of working with innovative packaging solutions: "When we talk about sustainable packaging, it's a broad concept that can include different types of films – not only those that are bio-based or bio-degradable. Even conventional fossil-based plastics can be sustainable if they are designed for recyclability or produced using recycled raw materials."

In the food sector in particular, the challenges around packaging are enormous. In this area, innovative plastic or bio-based materials must offer the same reliability as conventional materials.

To give just a few examples, grated cheese needs reliable, airtight packaging to protect the cheese from moisture and oxygen and prevent mould from forming. Coffee capsules have to be extremely tightly sealed to preserve the flavour and freshness of the coffee. This creates strict requirements with regard to barrier properties, enabling the packaging to be protected from oxygen, moisture and light. At the same time, the packaging must be heat-resistant to withstand the high temperatures while the coffee is being made in a pod machine.

Bio-based punnets for berries and grapes need to be highly sturdy to support the weight of the fruit and absorb impact during transport. At the same time, they must be breathable to prevent mould from forming while still preventing the fruit from drying out. In addition, these packaging solutions need to be transparent so that consumers can see the quality of the fruit on the shop shelf, which can be a challenge with bio-based plastics.

Yoghurt pots made of bio-based plastic require tightly sealed barriers to protect the yoghurt inside from oxygen and light and preserve its freshness. In addition, they must be stackable and stable without deforming, while also being easy to recycle or compostable. Another problem revolves around the packaging's suitability for different temperatures, as yoghurt is often stored in refrigerated units. By contrast, other foods such as salad or fruit need breathable packaging so that the food does not spoil.

Taghleef Industries has solutions ready for a whole host of different applications. "Food packaging in particular always depends on good barrier properties to keep products fresh and extend their shelf life", emphasises Muscatello. "We already have PP-based films with strong barrier properties in our product range. We are continuing to work on further optimising our NATIVIA® bio-based and bio-degradable films using coating and metallisation."

PP-based, bio-based and bio-degradable films for flexible packaging solutions differ from conventional plastic materials primarily in their composition and eco-friendliness.

PP-based films (polypropylene) are made from fossil raw materials. Bio-based films are made from renewable raw materials such as cornstarch. PHAs are a group of bio-degradable polyester materials produced by micro-organisms to store energy and carbon. The abbreviation PBSA refers to a bio-degradable polyester. It is commonly used in bio-degradable packaging materials and films due to its high degree of mechanical strength and flexibility. Bio-degradable films are often made from bio-based or fossil resources and break down into natural components under certain conditions (e.g. when composted). They offer a green alternative to conventional plastics but are often less durable.

"Our company makes polylactide PLA films that are bio-based and industrially compostable. In addition to PLA, we are now also certifying new bio-polymers such as PHA and PBSA to improve the films' bio-degradability and achieve a home compostability certification", says the product manager.

Worldwide, the consumption of bio-based and bio-degradable packaging is expected to increase by around 15 percent annually over the next few years (sources: Statista, Plastics Europe). Europe is currently leading the shift towards bio-based packaging materials, while the United States still relies more heavily on conventional plastics.

"The development of new materials is driven by a growing awareness of environmental issues and the need for more sustainable solutions", explains the packaging expert. "More and more consumers are placing a growing emphasis on sustainability, and this is increasing the pressure on businesses. There is a strong demand for bio-degradable and compostable packaging, especially in the food sector."

Alternative materials are still more expensive than conventional ones – but for reasons of competition, social responsibility and long-term potential cost savings, there is no other way forward.

In addition to this, EU legislation governing sustainable packaging is growing stricter, especially for food. New regulations are being introduced with a view to promoting the transition to a circular economy and reducing environmental impact.

One of the requirements in the Packaging and Packaging Waste Regulation (PPWR) is a set level of recycled content for certain packaging solutions by 2030. This means that a defined percentage of the material must be sourced from recycled material. Reusability of packaging and minimisation of material thickness to avoid unnecessary packaging are two more key concepts in this context. Since 2021, there has also been the Single-Use Plastics Directive (SUPD), which aims to reduce the amount of plastic packaging that is only used once.

The EU, then, is pursuing ambitious goals to make packaging more sustainable under its European Green Deal and Circular Economy Action Plan.

In addition, the bloc's EPR rules ensure extended producer responsibility. These specify that the organisation placing packaging on the market must be responsible for managing and recycling it. "Businesses that make an early switch to sustainable packaging solutions should generally be better prepared for future regulatory changes", says the product manager. "As a result, it is well worth it for organisations to gear themselves up for the future in good time."

Arriving at new solutions requires support and expertise. "At Taghleef Industries, we offer comprehensive services under our Redesign label. When we provide these services, we develop a bespoke solution for customers to switch from a traditional packaging structure to a more sustainable and innovative alternative", says Muscatello. "In doing so, we keep an eye on their specific requirements for product protection and product performance, combining these with the sustainability requirements at hand." Taghleef Industries also collaborates with suppliers of printing inks, adhesives and coatings to review their compatibility with newly developed films.

Participation in the SAVE FOOD project plays an important role in fostering collaboration with strong partners. "As an international producer of sustainable packaging materials in the food sector, we recognise that we have a role to play in actively combatting food waste", explains the committed plastics expert. "The SAVE FOOD platform offers us the opportunity to work with global partners to devise innovative solutions that improve food protection while also conserving resources and minimising environmental impact. Working together with other organisations committed to this goal around the world enables us to create a more sustainable future and conserve valuable resources together."