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a guide to technologies, strategies, and best practices for reducing plastic waste

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Paper

Packaging made of paper or other fiber-based materials can take many forms, including paper bags, paperboard, corrugated board, molded fiber, canisters, cartons, and paper cushion (4) (15). Gable-top and aseptic cartons have particularly common usage for liquid products such as juice, milk, and soup. The suitability of switching from plastic to paper or cardboard needs to be evaluated on a case-by-case basis. Brands and packagers should understand a number of key factors in their decision-making process.

Packaging weight: In some applications, paper packaging may be substituted without large weight increase, such as fruit and vegetable punnets, display trays, or food service items (plates, cutlery, straws) (7). Consultation with suppliers can help address any specific weight impacts for particular applications, which can then be useful in understanding transportation and other elements of environmental impacts.

Technical and practical recyclability: Generally, paper is a highly recyclable material, which can be repulped and reused seven times before the fibers become too short and weak (19). Some paper-based packaging combines paper with other materials or coatings that are necessary to improve functionality and barrier properties but that can impact the recyclability of the packaging. (7) (13) Additives designed to improve the wet-strength of paper packaging also may have implications for recyclability in repulping operations. (13) Companies are encouraged to consult with their suppliers to better understand technical recyclability performance for specific applications.

Recycled system status: As a broad category of materials, the recovery rate for paper and cardboard is higher than any other basic material and has been recovered at more than 65% for nearly ten years (12). Overall, there is still over 20 million tons of paper either landfilled or incinerated each year. (12)

Recycled content, circularity, and responsbily sourced fiber: Many paper products are capable of having high levels of recycled content and circularity, especially corrugated cardboard and uncoated paperboard.(20) Poly-coated cartons have lower capability of using recycled content and lower circularity back to packaging. Because of fiber loss through the recycling process, virgin fiber will be consistently needed in many applications. Sourcing sustainably produced fiber and making use of forestry certification systems is critical to avoiding unintended environmental impacts. (4)

Costs of paper packaging varies depending on the type of application and should be evaluated on a case-by-case basis. Plastic IQ estimates a cost increase of approximately 70% relative to single-use plastic packaging per ton single-use plastic being substituted by paper. These higher material costs are also caused by a weight increase since in some applications 50% greater weight of paper is re-quired for the same function as the equivalent single-use plastic packaging. Other costs of switching from plastic to paper should also be evaluated, for example potential impact on the speed of pack-aging production or filling lines. Companies should consult with their suppliers to better under-stand the full cost implications of switching their specific plastic to a paper based packaging format.

Paper and cardboard GHG emissions differ, depending on their production process, energy source, and end-of-life treatment. Paper packaging may require more material on average than plastic packaging by weight. However, even accounting for this weight increase, environmental studies indicate that sustainably sourced paper packaging could save emissions, but this depends on the details of paper sourcing and supply chain.

While well-managed forests for paper sourcing can be net carbon positive, greenhouse gas emissions of pulp and paper mills can differ widely depending on their production process. The energy mix in the electricity grid has a large influence on the total carbon footprint for mills that purchase electricity; mills that burn waste biomass tend to have lower overall emissions.

Beyond manufacturing, if paper ends up in landfills, it can decompose and form methane; although many landfills have effective gas recovery systems, robust recycling can help prevent landfilling and the potential impacts of methane. Beyond greenhouse gases and forest impacts, papermaking has environmental impacts on air and water quality (2); however, most of these issues are highly regulated by government authorities.

Beverage cartons can prevent the need for refrigeration during transportation and for the duration of the packaged product’s lifetime, affecting the potential GHG emissions reduction associated with this format. However, this may be variable and will only apply in certain applications, geographies, and transport distances rather than being true for all beverage cartons substituting rigid plastic (8).

Key Benefits

  • Reduction of non-renewable materials: Substituting plastic with paper will typically result in a lower usage of non-renewable re-sources. While papermaking fibers are renewable, many of the coatings and fillers are not. As such the source and the end of life of the non-fibrous materials should be kept in mind.
  • Increased recyclability: Paper packaging can present a viable solution for plastic films such as wraps and bags or as in protective packaging where molded fiber may substitute for expanded plastic foam. Cardboard packaging solutions that are more readily recyclable can substitute for less recyclable shrink film and plastic rings used for multi-pack bever-age.(1) Innovations in paper coatings are increasing acceptability of coated paper to paper recyclers, in particular food applications (2).
  • Increased recycled content: Heavier paper and cardboard used in rigid non-food packaging can be made with high lev-els of recycled content.100% recycled cardboard consumes high levels of residential mixed paper and is one of the pri-mary markets for this material.
  • Reduced need for refrigration: Some carton formats can prevent food spoilage while reducing the need for refrigeration, which in turn could be associated with lifecycle emissions reductions in some cases and ap-plications
  • Consumer preference: Consumers may appreciate paper and cardboard packaging for reasons of recyclability and practicability.

As mentioned above, a switch to paper based packaging needs to be evaluated on a case by case basis taking into account these factors. A switch to paper should consider GHG’s, refrigeration needs, sourcing of the fiber, packaging weight, costs, recyclability of the application, and overall recycling rates.

How to make it work

  • Recycled content and non-recycled feedstocks: Specifying recycled content and exploring highest possible levels reduces impacts of virgin production, supports the recycling collection system, and keeps reusable fiber out of landfills. However, paper can be repulped and reused up to seven times, so recycled fiber and new sustainable fiber need to be used in best ways as interdependent feedstocks. (4, 14). Sustainable forest management standards addresses a breadth of social and environmental aspects associated with timber harvesting. Companies should seek out certified sources to ensure fiber is being sourced responsibly. There are three types of paper certifications: forest management certifications, wood procurement certifications, and Chain of Custody (CoC) certifications (14). Programs such as the Forest Stewardship Council (FSC), The Programme for Endorsement of Forest Certification Schemes (PEFC), or the Sustainable Forestry Initiative Program (SFI) (2,4), have been adopted globally and certified products are widely available.
  • Ensuring compatibility with the recovery system: Ensure that paper recycling infrastructure is in place in practice and at scale and that your future packaging design is compatible with the recycling processes. Consider the availability of collection and sorting schemes as well as the probable fate of the packaging (1,4).
  • Design paper packaging for recyclability: There are many choices that can affect the recyclability of paper. Generally speaking, water soluble inks, dyes, adhesives and coatings cause few problems. The use of certain materials such as wet strength resins and non-paper materials (e.g. plastic windows or foils) can also be problematic.
  • Invest in innovation: Innovation in new materials, packaging designs and barrier coatings/alternatives for plastic linings are rapidly evolving and will likely improve the outcomes of paper packaging in the future. However, coatings and fillers should be compatible with the expected end of life of the product, (e.g. compostable or recyclable) and need to be applied and proven at scale. (2)
  • Clear identificaiton as paper: Ensure that any potential packaging alternative to plastic is either completely made from paper or that through labeling the plastic or other non-fiber parts are clearly distinguishable to support appropriate disposal/recycling. Recycling should be the preferred option, however there may be cases (e.g. with food contact) where composting of some kinds of paper packaging is a viable and/or a preferred solution.

Enabling system conditions

  • Improving recovery and recycling: Although corrugated cardboard enjoys very high recycling rates, other kinds of paper packaging do not have as high of recycling rates. An effective recovery system for all materials is an essential ingredient for the success of all packaging materials. Brands and packagers should recognize that they have a role to play in developing a robust U.S. recycling system that in turn delivers the environmental and economic benefits envisioned in sustainable packaging.
  • Support direct investments in recycling: Direct investments in recycling have the potential to accelerate the expansion of paper, cardboard and carton collection and recycling; increase recycled content in paper; and re-duce contamination (2). Continuing to increase the share of population with recycling programs is a critical enabler for justifying a shift to beverage cartons, for example.(9)
  • Paper recycling infrastructure and sourcing standards: Demand for recycled content helps incentivize and justify investments in paper recycling in-frastructure. At the same time, broader commitment to the use of sustainability standards for virgin fiber and to the use of paper recycling design guides helps ensure sustainable fi-ber sourcing and the use of paper packaging that is most compatible with the recycling sys-tem. (1,4,2)
  • Innovation of paper packaging: Participation in research and development and adoption of viable innovations to ensure coatings and barriers are recyclable is critical to the long-term success. (2)

Examples and case studies

  • Alkindo Naratama: They launched a green product as a substitute for the first plastic bubble wrap in Indonesia, namely Hexcel Wrap. This product is to reduce plastic waste which is widely used in e-commerce businesses. Hexcel Wrap is a sustainable product from ALDO as an alternative to bubble wrap in the form of a honeycomb structure made of recycled paper as a protection solution in packaging shipments of goods, especially for the e-commerce market.
  • PT Ajinomoto Indonesia: They launched the MSG Ajinomoto product using paper packaging. With this paper packaging innovation, Ajinomoto can reduce plastic use by up to 30%. In addition, reducing the use of plastic in other products such as: 8.4% Masako® in each 9gr package and 9.5% Sajiku in each package.
  • L'Oréal: In collaboration with an e-commerce platform, Shopee Indonesia launched an initiative to replacing bubble wrap and plastic tape packaging. The alternative is to use a flute liner, which is a corrugated material similar to cardboard, and paper tape as the adhesive distribution.