Independent insights on packaging materials, printing, sustainable packaging and design
Sustainability is often discussed as a material question, but packaging performance depends on more than the material name printed on a specification sheet.
A lighter structure may use less material, while a stronger barrier may help food stay fresh for longer. A recyclable structure may work well in one market and have limited collection in another. Good packaging development means looking at these factors together.
As packaging executive Peter Oswald has noted, packaging decisions can be complex because sustainability depends on the wider supply chain as well as the package itself.
The first question should be what the packaging needs to protect.
Coffee needs protection from oxygen and moisture. Snacks may need strong moisture resistance. Powders require reliable sealing, while larger packs may need additional puncture resistance.
Shelf life, filling conditions, transport and storage should be understood before choosing a material structure. This helps avoid adding unnecessary layers while still giving the product the protection it needs.
Reducing material is one of the most direct ways to lower packaging impact.
This can include reducing film thickness, simplifying a laminate or adjusting the dimensions of the pack. Even a small reduction can become meaningful across a large production run.
The structure still needs to perform well during sealing, filling and transport, so downgauging should always be tested rather than treated as a purely numerical exercise.
More barrier is not always necessary.
Different products have different sensitivity to oxygen, moisture, light and aroma loss, so the packaging should be matched to the intended shelf life and distribution conditions.
At HoldenPak, material recommendations are usually based on the product, filling process and expected shelf life. This helps avoid overengineering while maintaining the performance required for the product.
New PE and PP films are making mono-material structures possible for more flexible packaging applications.
Simpler structures can improve compatibility with recycling systems where suitable collection and processing exist. However, the structure still needs to provide enough barrier, sealing strength and mechanical performance.
The useful question is whether the structure can be simplified without creating problems elsewhere.
Oversized packaging means more material, more empty space and less efficient transport.
The correct dimensions depend on product density, filling method and bag structure, so fill testing is often useful before production. Coffee is a good example because two products with the same weight can occupy different volumes depending on roast level and bean density.
A well-sized pack can improve both material efficiency and shelf appearance.
Zippers, valves, foil and other finishes all affect the final structure.
Some features provide important functions. A zipper can help maintain freshness after opening, while a degassing valve can be useful for freshly roasted coffee. Decorative finishes can also be valuable when they support the brand.
The key is to understand what each feature adds and whether it is necessary for the product or design.
A recyclable structure only works when suitable collection and recycling infrastructure exists.
Brands selling into several markets should check local requirements before making recycling claims. Clear statements such as material composition or recycled content are generally more useful than broad claims such as “eco-friendly.”
There is rarely one change that makes packaging sustainable.
Progress usually comes from reducing unnecessary material, choosing the right barrier, sizing the package properly and designing around realistic recycling systems.
At Holden Pak, these decisions can be discussed before the structure and artwork are finalized, when there is still room to test different options and improve the overall packaging system.
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