The Paperisation of Christmas: Are we getting packaging right?

The festive season is here, and what better time to unwrap the progress, or the pitfalls, of a year in packaging innovation? From milk cartons to the latest debut of the Quality Street paper tub, the push for seemingly environmentally friendly materials is as lively as ever. But is there a clear winner in the "sustainable packaging" race, or are we simply guessing and not testing? 

Take Quality Street, for example: this year, they’ve introduced a paper tub for their iconic chocolates. Yet, plastic tubs are still part of the line-up, hinting at a mix of experimentation and market testing. It's a clear sign of the packaging industry grappling with an increasingly complex question: what is truly the best material to use? And that all-important question of ‘what will have the cheaper Extended Producer Responsibility (EPR) fees?’ 

The full picture: From cradle to cradle 

To really understand the environmental points, we need to examine materials thoroughly, considering every stage of their lifecycle, from raw material extraction to disposal or reuse. This "cradle-to-cradle" analysis can reveal some stark truths. 

Plastic: Yes, virgin plastic is made from fossil fuels; a non-renewable resource extracted through energy-intensive drilling that contributes to negative environmental outcomes. Once produced, plastic is durable and lightweight, and a lot of plastic can be recycled, reducing transportation emissions compared to heavier materials. But it’s also infamous for its longevity as waste, with billions of tons accumulating in overseas landfills, waterways or oceans where recycling infrastructure is poor or non-existent. And even though the UK infrastructure - with Biffa a vital part of that - recycles the vast majority of collected plastics, we must also acknowledge that it cannot be recycled infinitely. The Polymer chains in the mechanical process of recycling keep getting shorter and shorter - just like with the long fibres in paper recycling - until such point that they can no longer be recycled except in a chemical process. 

Aluminium: Often seen as a greener alternative, virgin aluminium requires mining bauxite ore, a process linked to deforestation, water contamination, and high energy use. However, aluminium shines in its recyclability, with nearly 75% of all aluminium ever produced still in use today. Aluminium can be recycled forever without losing quality. 

Paper: Paper-based packaging is renewable and recyclable – always a great story. However, the surge in demand from brands swapping materials raises questions about the responsibility of sourcing. Certifications such as Forest Stewardship Council (FSC) offer some assurance of responsible sourcing, but with more demand for paper-based packaging, this can increase unmanaged logging, which can threaten biodiversity and ecosystems. 

Steel: Steel, a material often used in industrial and rigid packaging, is made primarily from iron ore in energy-intensive processes that generate substantial greenhouse gas emissions. However, steel’s durability and infinite recyclability make it a standout in sustainable packaging options. Recycled steel is widely used in packaging, such as cans, reducing the reliance on virgin resources. Steel’s magnetic properties also make it easy to recover and recycle from waste streams using magnets, further supporting a circular economy for packaging materials. 

Glass: Glass, commonly used in packaging for food and beverages, is made from natural materials like sand, soda ash, and limestone, and requires significant energy to melt and form. However, glass is highly recyclable, making it a sustainable option in packaging. The recycling process for glass is less energy-intensive than creating new glass from raw materials, and recycling reduces emissions. While glass is heavier than plastic, which can increase transportation emissions, its ability to be fully recycled and reused in the packaging cycle makes it a valuable material for reducing long-term waste. 

EPR fees 

Extended Producer Responsibility (EPR) for packaging requires businesses to take responsibility for the environmental impact of the packaging materials they supply or use. From 2024, businesses meeting specific thresholds must register, report packaging data, and pay fees to cover waste management costs. EPR fees (illustrative fees below) encourage sustainable packaging choices and accountability. Ensure compliance by understanding your obligations, thresholds, and deadlines to avoid penalties. Start by reviewing your packaging usage and data now, and if you need support, please get in touch here.