Top questions about paper-based packaging – answered by the experts.

Are there barrier options within paper-based packaging for products that are highly sensitive to light, moisture, and temperature – for example, potato chips/crisps? Even metallized plastics can struggle to meet shelf-life requirements.

Pieter: Yes, thanks to developments in paper-based packaging over the past few years, it is now a real option even for sensitive products. AmFiber™ Performance Paper provides optimized OTR (Oxygen Transmission Rate) and WVTR (Water Vapor Transmission Rate) values and is available with or without a barrier to light. While achieving consistent hermetic sealing can be more challenging with paper-based packaging, the right combination of material and packing machinery ensures that the required shelf life is maintained– even for highly sensitive products like crisps.

Are there specific regulatory challenges for fiber-based packaging in the UK recycling system?

Daniele: Yes, in some cases. The UK has more stringent paper recycling targets under its Extended Producer Responsibility (EPR) scheme than the European Union does currently. However, Amcor has developed AmFiber™ solutions that meet these UK-specific requirements, ensuring compatibility with UK sorting and recycling systems.

How do you seal paper-based packaging? Could high sealing temperatures damage the material?

Pieter: Paper is quite heat-resistant and can withstand temperatures up to 200°C when proper sealing times and pressure settings are used. With the correct process parameters and tooling, no material damage occurs.

Is grease resistance achievable in paper-based packaging?

Daniele: Yes, absolutely. Amcor conducts Klemm Immersion Test (KIT) testing as a standard for our paper-based solutions. We offer grades ranging from no grease resistance to full resistance (KIT level 12), depending on the application.
What is KIT Testing? KIT testing assesses how resistant a paper surface is to penetration by oils and greases. This is essential for most food packaging, ensuring that greasy contents (such as pastries, or snacks) don't compromise the pack's appearance or performance.

Can the barrier in paper-based packaging still perform well in tropical conditions?

Pieter: Yes, it can. Amcor, by default, tests packaging performance at 38°C and 90% relative humidity. Our paper-based barriers are engineered to maintain moisture and heat resistance, ensuring product protection even in hot, humid environments. As a global supplier, we are developing paper-based packaging solutions for a wide range of markets. Even for challenging climates, such as that in Southeast Asia, we have successfully conducted market studies that demonstrate barrier compliance with shelf-life requirements under local conditions.

Is paper-based packaging compostable?

Daniele: Some paper-based packaging is compostable, but not all. Amcor has developed a line of paper-based products are both recyclable and compostable, called AmFiber™ Dual Life. Before prioritizing compostability, we recommend an assessment of the packaging’s application – what will go inside the pack, will the pack potentially be disposed of with food remains inside (e.g. a tea bag or take-out container) and is a drop-off point for a composting stream readily available to consumers? Often the greater environmental benefit lies in making packaging recycle-ready, which ensures broader integration into existing waste systems and delivers more scalable impact. Our team is happy to consult with brands to help guide these decisions.

From a consumer-appeal point of view, our consumer research(1) revealed that the top two packaging claims to positively influencing purchasing decisions are: recyclable packaging and compostable packaging.

This clearly shows that both features strongly resonate with shoppers. Recyclability remains critical due to its alignment with existing waste infrastructure, while compostability appeals to growing consumer interest in natural packaging materials.

To unlock the full potential of more sustainable packaging, brands can aim to deliver solutions that offer either, or ideally both, attributes. Combining recyclability with compostability enhances environmental performance and speaks directly to today’s conscious consumer.

How does the machine speed of paper-based packaging compare to other materials like plastic?

Pieter: The assumption is often that a switch to paper-based packaging means a significant sacrifice of run speed. The actual run speed of paper varies based on format, sealing method, and machinery:

• For larger formats (20–60 packs per minute), there’s typically no significant speed drop, especially when using the right tooling.

• For smaller formats (>100 packs per minute) that use heat sealing, paper may reduce line speed unless sealing tools are upgraded.

Because paper transfers heat differently than plastic, achieving consistent seal quality at very high speeds may require adjustments to sealing tools or sealing parameters. However, for cold-seal applications, paper performs as well as plastic, achieving comparable speeds with minimal changes. These days, we see OEM partners come with modified solutions that help overcome that difference between paper and plastic packaging.

Source:

1. March 2024, based on 3,180 respondents in UK, France, Spain, Germany, Poland, and Italy