What Are the Most Sustainable Packaging Material Options?

Sustainability is on everyone’s mind, especially when it comes to packaging. For small and medium-sized businesses, finding eco-friendly packaging options can be a bit of a puzzle. You may have been putting it off, but customers are looking for brands that care about the environment, and your packaging choices are a big part of that story.

In this guide, we’ll dive into what makes packaging sustainable, explore popular eco-friendly materials, and help you pick the best options for your business. Let’s make sure your packaging is as green as your intentions!

What Is Sustainable Packaging?

Sustainable packaging involves choosing materials and methods that are kinder to the environment. It’s about making smart choices that reduce waste and lower your carbon footprint. Whether through better materials or thoughtful processes, the goal is to create packaging that serves its purpose without causing harm to the planet.

It’s also crucial to consider the full life cycle of packaging – known as Life Cycle Assessment (LCA) – to gauge its true environmental footprint. You need to think about every step along the way, from production of raw materials to disposal, to get the full picture.

To help, here are a few things that will contribute to the ultimate sustainability of your packaging. Don’t worry if it’s overwhelming - working on just a few components can still make a big difference!

Biodegradable

Biodegradable packaging is designed to break down naturally over time with the help of microorganisms like bacteria and fungi. Unlike traditional plastics, which can linger in the environment for centuries, biodegradable materials decompose into natural elements such as water, carbon dioxide, and biomass. This process typically occurs under specific conditions, like exposure to sunlight, air, and moisture.

However, just because a material is biodegradable doesn’t mean it’s the perfect solution! The rate and completeness of biodegradation can vary, and not all biodegradable materials break down quickly or harmlessly in all environments. That’s why understanding where and how your packaging will decompose is essential to making a truly sustainable choice.

Compostable

Compostable packaging goes a step further than biodegradable materials by not only breaking down naturally but also doing so in a way that enriches the soil. Compostable packaging is designed to decompose fully into non-toxic components, like water, carbon dioxide, and organic matter, within a specific timeframe, usually in a composting environment.

Again, compostable materials need the right conditions – such as the heat and moisture found in composting facilities – to break down effectively. If these conditions aren’t met, the material may not decompose as intended. This makes it important to ensure that compostable packaging is disposed of correctly, so it can return nutrients to the earth instead of ending up in a landfill.

Recyclable

Recyclable packaging is one of the most recognised and widely promoted concepts in sustainability. It refers to materials that can be reprocessed and reused to create new products, reducing the need for virgin resources. Common recyclable materials include paper, cardboard, glass, and certain plastics.

However, recycling isn’t as straightforward as it seems! While many products are labelled as recyclable, only a fraction actually gets recycled. For example, in the UK, about 44% of household waste is collected for recycling. However, only a fraction of that fraction is eventually recycled, while much of it is exported abroad and lost to a complex global supply chain.

In short, contamination and inadequate recycling infrastructure often mean that not all recyclable materials live up to their potential. When choosing recyclable packaging, it’s essential to consider not just the material itself but also the likelihood that it will actually be recycled in practice.

Renewable

Renewable packaging materials come from resources that naturally replenish over time, such as plants or trees. Unlike finite resources like petroleum, which is used to make traditional plastics, renewable materials are more sustainable because they can be grown and harvested repeatedly. Common examples include paper, cardboard, and plant-based plastics.

However, it’s important to consider how these resources are managed. Sustainable sourcing is key: using renewable materials is only beneficial if the resources are responsibly grown and harvested without harming ecosystems or depleting natural reserves.

Environmental Impact

In truth, there’s a lot more to consider than just the material properties of your packaging – you need to understand the broader effects of your packaging on the planet. It involves evaluating multiple factors to get a complete picture of how sustainable a packaging material or process really is, like:

Carbon Footprint: The total greenhouse gases emitted during the packaging’s life cycle, from production to disposal.
Energy Consumption: The energy needed for production, transport, and disposal.
Waste Reduction: Efforts to minimise waste, such as using less material and designing for recyclability.
Pollution: Potential pollution, including plastic in oceans, chemical leaching, and microplastics.

You’ll never fill in every blank, but taking efforts to understand these factors will help in making informed, environmentally responsible packaging choices. Who said any of this was easy?

What Does Eco-Friendly Really Mean?

Eco-friendly packaging isn’t just about using the right materials – it’s about adopting a holistic approach to reduce environmental impact.

While using sustainable materials is important, the first step should be to consider whether packaging can be minimised or eliminated completely. Using less packaging in the first place is often the most effective way to lessen your environmental footprint.

Again, being truly eco-friendly involves looking at the entire life cycle of your packaging – from production to disposal – and making choices that benefit both your business and the planet. Keep this in mind as we share some sustainable material options - these materials alone are not the answer!

Sustainable Packaging Materials

When it comes to sustainable packaging, you’ve got a lot of options. Whether you’re after something recyclable, compostable, or made from renewable resources, there’s a material out there that fits the bill.

In this section, we’ll run through some of the top choices, breaking down what makes each one a good option for your business. From recycled paper to plant-based innovations, we’ll help you find the right fit for your packaging needs.

Recycled Paper and Cardboard

Recycled paper and cardboard are made from post-consumer waste and are great for reducing your environmental footprint. These materials are versatile, easy to work with, and a familiar choice for many businesses.

Advantages

Helps cut down on waste by reusing existing materials.
Easy to recycle again, supporting a circular economy.
Usually more affordable than other sustainable options.

Disadvantages

Not as durable as virgin materials.
Doesn’t offer much protection against moisture.
Recycling still requires energy and resources.

Best Use Cases

Shipping boxes for non-fragile items.
Simple, eco-friendly packaging solutions.
Printed materials like labels that need to be recyclable.

Kraft Paper

Kraft paper is a strong, durable type of paper made from wood pulp through the kraft process. It’s unbleached, which gives it that natural, brown appearance, and is known for being both eco-friendly and versatile. Kraft paper is a popular choice for wrapping, padding, and other basic packaging needs.

Advantages

Strong and durable, ideal for wrapping and padding.
Made from renewable resources and biodegradable.
Can be recycled, making it a sustainable option.

Disadvantages

Limited moisture resistance.
Not as visually appealing for premium packaging.
Can be rough and difficult to print on.

Best Use Cases

Wrapping and padding products for shipping.
Simple, rustic packaging for small businesses.
Eco-friendly mailers and bags.

Plant-Based Materials

Plant-based materials are an innovative category of sustainable packaging made from renewable sources like crops and agricultural by-products. These materials offer an eco-friendly alternative to traditional plastics and can be biodegradable or compostable, depending on the specific type.

Hemp

Hemp packaging is made from the fibres of the hemp plant, known for its strength and sustainability. Hemp is a fast-growing, renewable resource that requires minimal pesticides and water, making it an eco-friendly alternative to traditional materials. It’s used for everything from paper products to fabric-like wraps and padding.

Advantages

Strong and durable, ideal for various packaging needs.
Grows quickly with minimal environmental impact.
Biodegradable and compostable.

Disadvantages

Can be more expensive than other sustainable options.
Limited availability and higher production costs.
Coarser texture may not be suitable for all products.

Best Use Cases

Sturdy packaging for heavy or fragile items.
Premium, eco-conscious brands that can absorb higher costs.
Products where durability and strength are key.

Cornstarch

Cornstarch packaging is made from the starch derived from corn kernels. It’s a biodegradable and compostable material that serves as an alternative to traditional plastic packaging. Cornstarch is particularly suitable for businesses seeking eco-friendly solutions without significantly compromising on packaging performance.

Advantages

Biodegradable and compostable under industrial composting conditions.
Made from a renewable and widely available resource.
Provides a similar texture and strength to traditional plastics.

Disadvantages

Requires industrial composting facilities, limiting disposal options.
Potentially higher cost compared to other eco-friendly materials like recycled paper.
Can divert resources from food production, which may be a concern in some industries.

Best Use Cases

Packaging for single-use food items where composting infrastructure is available.
Protective packaging for fragile goods where plastic-like strength is needed.
Food packaging where shelf life and product integrity are important.

Mushroom

Mushroom packaging is made from mycelium, the root structure of mushrooms, which binds together agricultural waste like hemp or corn husks. This innovative material is fully biodegradable and compostable, providing a strong and natural alternative to plastic foams used in protective packaging.

Advantages

100% biodegradable and compostable.
Grows using agricultural waste, making it highly sustainable.
Offers excellent cushioning and protection, similar to foam.

Disadvantages

Higher cost and limited availability.
Longer production times due to the natural growing process.
Not suitable for all packaging needs, especially where flexibility is required.

Best Use Cases

Protective packaging for delicate or high-value items.
Eco-conscious brands looking for innovative packaging solutions.
Products where strong, natural cushioning is needed.

Seaweed

Seaweed packaging is made from the fast-growing marine plant, which can be harvested sustainably without the need for freshwater or fertilisers. This biodegradable material is often used to create flexible packaging, such as films and sachets, making it an innovative alternative to traditional plastics.

Advantages

100% biodegradable and compostable.
Grows rapidly and sustainably, without freshwater or agricultural inputs.
Naturally abundant and can be harvested without damaging ecosystems.

Disadvantages

Limited scalability and higher production costs.
May not be suitable for all packaging types, particularly those requiring rigidity.
Still relatively new, with limited availability.

Best Use Cases

Packaging for single-use items like sachets or wraps.
Eco-conscious food packaging, especially for perishable goods.
Brands aiming to stand out with innovative, ocean-friendly materials.

Bagasse

Bagasse is the fibrous byproduct left after extracting juice from sugarcane. Instead of letting it go to waste, it’s turned into a sturdy, compostable material perfect for packaging. Bagasse is often used for food containers and tableware, offering a practical and sustainable alternative to plastic and Styrofoam.

Advantages

Made from a renewable byproduct, reducing waste.
Fully biodegradable and compostable.
Strong and heat-resistant, great for food packaging.

Disadvantages

Limited availability outside of specific regions.
Can be more expensive than traditional materials.
Not waterproof without an added coating.

Best Use Cases

Eco-friendly food packaging, especially for takeout.
Sturdy containers for hot or greasy foods.
Businesses looking to repurpose agricultural waste.

Coconut

Coconut husk, or coir, is the fibrous material found between the hard shell and outer coat of a coconut. It’s a natural, biodegradable material often used for eco-friendly packaging, especially as a sustainable alternative to synthetic fillers and cushioning. Coir is tough, durable, and repurposes what would otherwise be waste.

Advantages

Biodegradable and compostable.
Strong, durable, and naturally resistant to bacteria and mould.
Reuses a byproduct, minimising waste.

Disadvantages

Limited availability and higher cost.
Rough texture may not be ideal for all products.
Can be bulky, increasing shipping costs.

Best Use Cases

Protective cushioning for fragile items.
Eco-friendly packaging with a natural, rustic feel.
Brands focused on using agricultural byproducts.

Bioplastics

Bioplastics are a type of plastic made from renewable plant-based sources, such as corn, sugarcane, or potato starch, instead of petroleum. These materials aim to reduce reliance on fossil fuels and often have the added benefit of being biodegradable or compostable.

Polylactic Acid (PLA)

Polylactic Acid (PLA) is a bioplastic derived from fermented plant starch, typically corn. It’s widely used in packaging, from disposable cups to food containers, and is known for being biodegradable under industrial composting conditions. PLA offers a plastic-like feel while being a more sustainable option.

Advantages

Made from renewable resources like corn.
Biodegradable in industrial composting facilities.
Versatile and can mimic traditional plastics.

Disadvantages

Requires specific composting conditions, limiting disposal options.
Can be more brittle than traditional plastics.
Not biodegradable in natural environments like landfills.

Best Use Cases

Disposable food packaging where industrial composting is available.
Packaging for products that benefit from a plastic-like appearance and feel.
Eco-friendly alternatives to traditional plastic products.

Polyhydroxyalkanoate (PHA)

Polyhydroxyalkanoate (PHA) is a bioplastic produced by bacterial fermentation of sugars or lipids. It’s fully biodegradable and can break down in various environments, including soil and water, making it one of the most eco-friendly bioplastics available. PHA is used in packaging, agricultural films, and medical products.

Advantages

Fully biodegradable in natural environments.
Made from renewable resources.
Versatile and suitable for various applications.

Disadvantages

Higher production costs compared to other bioplastics.
Limited availability.
Not as widely used, so less infrastructure for disposal.

Best Use Cases

Packaging for leading environmentally conscious brands.
Applications where biodegradability is crucial, like agricultural films.
Medical products that require a high degree of biodegradability.

Biodegradable Plastics

Biodegradable plastics are designed to break down more quickly than traditional plastics when exposed to the right environmental conditions. Unlike bioplastics, which are made from renewable resources, biodegradable plastics can be made from both renewable and non-renewable sources. The key is that these materials are engineered to decompose more readily, often requiring specific conditions such as heat, moisture, and microbial activity.

Advantages

Breaks down faster than traditional plastics under the right conditions.
Can be used in a wide range of applications similar to conventional plastics.
Reduces long-term plastic pollution.

Disadvantages

Requires specific conditions to biodegrade, which may not always be available.
Can still produce microplastics if not properly managed.
Potential confusion for consumers between biodegradable and compostable products.

Best Use Cases

Short-term use items like packaging films and disposable utensils.
Situations where traditional plastic performance is needed but with a reduced environmental footprint.
Products where there’s a likelihood of proper disposal in controlled environments, like industrial composting facilities.

Metal

Metal packaging, commonly made from aluminium or steel, is known for its durability and recyclability. It’s widely used for food and beverage containers, as well as other products that require strong, protective packaging. Often overlooked, metal is actually one of the most recycled materials, making it a solid choice for businesses focused on sustainability.

Advantages

Highly durable and protective.
Infinitely recyclable without losing quality.
Resistant to moisture, light, and oxygen, preserving product freshness.

Disadvantages

Energy-intensive to produce.
Heavier than other packaging options, potentially increasing shipping costs.
Not biodegradable.

Best Use Cases

Packaging for beverages like cans and bottles.
Food preservation, especially for long shelf-life products.
Products requiring robust protection against environmental factors.

Glass

Glass is a classic packaging material known for its purity and recyclability. Made primarily from sand, soda ash, and limestone, glass is inert, meaning it doesn’t interact with the products it contains. It’s widely used in food, beverage, and cosmetic industries, offering both a premium look and effective product protection.

Advantages

100% recyclable and can be recycled endlessly without loss of quality.
Non-reactive, preserving product integrity.
Offers a premium appearance and feel.

Disadvantages

Heavier than most packaging options, increasing shipping costs and carbon footprint.
Fragile and prone to breakage.
Energy-intensive to produce.

Best Use Cases

Packaging for beverages, like bottles for wine or juice.
Premium products where appearance and preservation are key.
Items requiring long shelf life without contamination risks.

What to Consider When Choosing Sustainable Packaging

As we laid out at the beginning, sustainable packaging isn’t just about the right material – it’s about finding the best fit for your business and the planet. You’ll want to think about things like how much it costs, how it impacts the environment, and whether it’s practical for your needs.

In this section, we’ll walk through the key factors to help you make choices that are good for both your business and our world.

Reduction

When it comes to sustainable packaging, less is more. Reducing the amount of packaging you use is usually the most effective way to minimise your environmental impact. By cutting down on materials, you not only save on costs but also reduce waste and the energy needed for production and disposal.

Start by evaluating whether all elements of your current packaging are necessary, and look for ways to simplify. Often, the greenest option is simply using less.

Life Cycle Assessment (LCA)

Life Cycle Assessment (LCA) is a tool used to evaluate the environmental impact of packaging throughout its entire life cycle – from raw material extraction to disposal.

To carry out an LCA, start by mapping out each stage of your packaging’s life: production, transportation, use, and end-of-life. For each stage, assess factors like energy use, emissions, waste generation, and resource depletion. The goal is to get a full picture of the environmental footprint and identify areas where you can make improvements.

Compatibility

It might be obvious, but make sure your packaging fits your product and processes. It’s not just about size and shape: think about things like how the packaging might react to temperature changes during transit or whether it will stack well in storage. For instance, certain materials might warp or weaken if exposed to humidity, potentially compromising your product.

So, while compatibility might seem straightforward, taking the time to consider every angle can save you headaches and costs down the line.

Cost-Effectiveness

Let’s face it: sustainability has to make financial sense, too. When choosing packaging, it’s crucial to balance eco-friendliness with your budget. Consider not just the upfront cost of materials but also long-term savings from things like reduced waste, lower shipping costs due to lighter materials, or even potential tax incentives for using sustainable options.

And don’t forget to factor in the value of customer perception – sometimes spending a bit more on greener packaging can pay off in brand loyalty and reputation.

Durability

While you want something eco-friendly, your packaging also needs to hold up during shipping, storage, and handling. Consider how well the packaging protects your product from damage, moisture, or extreme temperatures.

Lightweight materials might reduce shipping costs but could compromise protection, leading to more waste from damaged goods. Striking the right balance between sustainability and strength ensures that your packaging does its job without costing you and the planet more in the long run.

Reusability

Reusability can be a smart choice for businesses looking to add value while reducing waste. If your packaging can be repurposed by the customer – like sturdy boxes, jars, or bags – it extends the life of the material and keeps it out of the landfill.

This might not be relevant for all products, but for certain items, reusable packaging can enhance the customer experience and encourage brand loyalty. It’s a way to turn your packaging into something more than just a one-time use item.

End-of-Life Management

End-of-life management is about what happens to your packaging once it’s done its job. Can it be recycled, composted, or safely decomposed? Thinking about the end-of-life stage helps ensure that your packaging doesn’t just end up in a landfill.

Choose materials that are easy for customers to dispose of responsibly wherever they are based, and consider educating them on how to do so. Whether it’s through clear recycling labels or offering take-back programs, managing the end of your packaging’s life is crucial for true sustainability.

Availability

When choosing sustainable packaging, it’s important to consider how readily available the materials are. Some eco-friendly options, like mushroom or seaweed-based packaging, may be harder to source, especially in large quantities. Limited availability can lead to higher costs and longer lead times, which could impact your business operations.

Before committing to a sustainable packaging material, make sure you can reliably access it in the quantities you need, even as your business grows. This ensures that your packaging strategy is both sustainable and practical.

Customer Reception

The right packaging for your customers is about more than just going green. Think about the message your packaging sends: Does it align with your brand values? Will customers see it as thoughtful or just another attempt at greenwashing?

It's also worth considering the tactile experience – how the packaging feels and functions. Sustainable doesn’t have to mean dull. High-quality, eco-friendly packaging that feels good in the hand can elevate the unboxing experience, turning it into a memorable part of your brand story.

Ditch the Drama, Embrace Sustainable Fulfilment

Feeling overwhelmed by the switch to sustainable packaging? We hear you! It's a fantastic step for the planet, but figuring it all out while fulfilling orders can become a real headache. Here at Tap’in, we want to be your partner in building a better world.

We’ll take care of ecommerce fulfilment from pick and pack to dispatch, whatever your packaging materials – recycled cardboard or those cool mushroom-based boxes. We’re equipped to store a variety of sustainable materials, and our crack team can handle your kitting or assembly needs to minimise waste – that's a win-win for your wallet and the environment!

Ready to ditch the fulfilment drama and focus on what your business does best? Get in touch today to find out how we can streamline your operations and help make your eco-friendly switch as smooth as, well, recycled silk.