Paper and Fibre Packaging

Introduction

Paper and Fibre-based Packaging

This guide addresses paper-based primary packaging solutions widely used for produce and food in formats such as: paperboard cartons, gable-top and aseptic cartons and molded fibre containers.

Consumers often view paper-based packaging as more environmentally-friendly compared to plastic packaging, with much of this attributed to paper’s recyclability, and rates of actual recycling, compared to that of plastic.  However, as this research notes, recyclable items — even when recycled — may have higher impacts due to factors such as material type and weight. For a more complete picture decision-makers must aim to consider the full life-cycle of any given product-packaging system.

A good place to start is sourcing.  Where most virgin plastic is derived from finite, fossil-based sources, paper-based packaging feedstock is renewable.  However, the extent to which renewable equates to sustainable depends heavily on resource management practices. For example, there are third-party chain-of-custody certification programs for sustainable forest management: Forestry Stewardship Council (FSC) and Sustainability Forestry Initiative (SFI) are commonly seen on food packaging in North America, and the Programme for Endorsement of Forest Certification (PEFC) is an umbrella organization recognizing different national programs.  Note that these certification programs have critics, including organizations like the Rainforest Action Network.  

Other sourcing considerations include the use of recycled material (see for example Recycled Paperboard Alliance), and the use of PFAS (per- and polyfluoroalkyl substances).  For many years PFAS have been approved as grease-proofing agents in a relatively small sub-set of food packaging — such as microwave popcorn bags, take-out containers, and pet food bags — to prevent oil and grease from leaking.  Both the Government of Canada and the US Environmental Protection Agency (EPA) are pursuing steps to address these chemicals, and some organizations have already taken action.  For example, the Biodegradable Products Institute (BPI) certified compostable packaging standard prohibits the use of PFAS.

Manufacturing is another important consideration. For example, the pulp and paper industry (PPI), like the petrochemical industry (for plastics), uses high amounts of energy to generate products. As noted here, processes like chemical pulping, black liquor evaporation, and drying require significant energy.  So, an important question to ask suppliers is: “What efforts are being made to minimize the environmental impacts of manufacturing processes?” 

 Having considered upstream impacts associated with sourcing and manufacturing one can then consider recyclability, as non-fiber elements can create challenges for recyclers. Many are listed in this AFPA Design Guide, and include: barriers, coatings, adhesives, metals, polymer windows, wet-strength resins, and pressure-sensitive labels.  Removing, limiting, or finding better alternatives for these elements is important to improve the quality of recycled material.

Paperboard

Paperboard applications vary widely, with a few in produce, and many in the broader food sector.  As noted, key considerations typically relate to sourcing, manufacturing impacts, and non-fiber elements that impact recyclability.

Cartons

Cartons are used for many liquid products, in dairy and other food segments. Evidence indicates that cartons often offer reduced environmental impacts when compared with single-use alternatives.  This article shows how integrated product and packaging processes offer reduced carbon emissions and water usage, and this article highlights testing of alternatives to the aluminum layer, which is less than 5% of a package, but about one-third of GHG emissions.

Here is a map of carton recyclers which includes one Canadian-based recycler.  When recycled, the fibre component is often used in paper towels, tissues and office paper. The polyethylene and aluminum (polyAl) components are harder to recycle, though they can be incorporated into products such as flower pots, pallets, and ceiling/roofing tiles. 

Molded Fibre

Molded fibre is used for egg cartons, as well as takeout containers. As described here, molded fibre products are formed directly from a slurry phase, and typically rely on “wet end” additives, which may include PFAS, to improve oil and water barrier properties.