Nestle recently announced a packaging makeover for one of its most recognizable products, nclick="javascript:window.open(https://www.packaging-gateway.com/news/nestle-kitkat-paper-wrapper/, _blank, noopener); return false;">KitKat. In Australia, the sweet treat will be trialed with recyclable paper wrappers as part of the company’s pledge to slash the use of virgin plastics by a third by 2025.

Nestle isn’t alone – other FMCG brands have begun migrating to paper-based alternatives as consumer demand for sustainable packaging alternatives soars.

I explore whether paper-based alternatives are the best long-term solution over traditional plastic packaging for food products.

Meeting food preservation requirements

On the surface, paper food packaging seems like the more environmentally friendly option for its biodegradable properties. However, food packaging manufacturers need to consider whether paper-based alternatives can realistically match, or even exceed, plastic packaging for food preservation without impacting its sustainable credentials.

Paper packaging has poorer barrier properties than plastic, making food products more susceptible to light, oxygen, and microbial degradation. To combat this, paper packaging manufacturers have previously resorted to additional coatings, typically plastic film, aluminum, or chemical coatings (PFAS). While these do provide the necessary protections for food preservation, these added coatings render paper packaging neither biodegradable nor recyclable.

Additionally, the nclick="javascript:window.open(https://news.bloomberglaw.com/environment-and-energy/pfas-bans-restrictions-go-into-effect-in-states-as-year-begins, _blank, noopener); return false;">banning of harmful PFAS is something many states are adopting throughout 2023 – New York, Maine, California, Pennsylvania, and Colorado have already enacted PFAS bans and restrictions, with other states expected to follow suit. While this has a wider impact on many household goods, including cosmetics, cleaning products, water-repellent clothing, and non-stick coatings for cookware, etc., it directly affects paper food packaging that relies on PFAS to prevent packaging degradation from grease and liquid.

In response to this, emerging technologies are hoping to provide improved barrier solutions for paper packaging. For example, water-based dispersion coatings are currently in development that aim to allow paper packaging to be fully recycled without separation processes while providing resistance to liquid and grease.

However, until these new technologies can be thoroughly tested in a practical sense, it will be some time before the industry experiences widespread uptake of 100% paper-based packaging.