What are the alternatives to plastic packaging?

Paper and carton board can provide alternatives to plastic across a range of packaging applications, including folding cartons, food trays, sleeves, punnets, cups and other food-service formats.

The right material depends on what the packaging needs to do. Strength, stiffness, grease resistance, moisture resistance, temperature tolerance, food-contact requirements, printability and the way the pack will be converted all influence the specification.

For some applications, a conventional folding boxboard or kraft board may provide the required performance. Where food, grease, moisture or temperature create additional demands, specialist barrier boards can provide properties traditionally associated with plastic packaging.

The starting point is therefore the function of the existing packaging and the performance the paper-based alternative needs to deliver.

Start with what the packaging needs to do

Moving from plastic to paper or carton board should begin with the technical requirements of the pack.

Consider:

What is being packaged?

Does the packaging come into direct contact with food?

Does it need grease resistance?

Is moisture resistance required?

Will it be used in chilled or frozen conditions?

Does it need to withstand microwave or oven temperatures?

How much stiffness and structural strength are required?

Does it need to be heat sealed?

What printing process will be used?

How will the board be cut, creased, folded and formed?

What happens to the packaging after use?

Answering these questions makes it easier to identify where a conventional carton board will perform successfully and where a specialist barrier board is required.

Folding boxboard can replace plastic in many carton applications

Folding boxboard is widely used for packaging where stiffness, print quality and good converting performance are important.

White-backed GC1 boards provide a clean, high-quality appearance and are particularly suited to premium packaging. Cream-backed GC2 boards combine strength and durability with a more natural reverse.

Depending on the grade, folding boxboard can be used across food and drink, pharmaceutical, cosmetics, retail and presentation packaging. Denmaur's carton board range includes GC1 and GC2 grades for a variety of packaging requirements.

When considering folding boxboard as an alternative to plastic packaging, the specification should take account of caliper, grammage, stiffness, surface finish, print requirements and the physical demands placed on the finished carton.

Barrier board can extend where paper-based packaging can be used

Food and food-service packaging often requires more from the substrate than structural strength alone.

Grease, moisture, temperature and direct food contact can all affect the performance required from the board.

Specialist barrier boards are designed to provide additional protection while retaining the advantages of a fibre-based packaging material.

Denmaur's barrier board range includes products developed specifically for food and food-service applications.

This makes barrier performance an important consideration when assessing whether a plastic format can move to paper or carton board.

Delipac provides a plastic-free barrier packaging option

Delipac is one of the clearest examples of where paperboard technology can replace functions traditionally provided by plastic.

It is a plastic and PFAS-free barrier packaging board designed for direct food packaging. Depending on the grade, applications include food cartons, trays, punnets, cups and other formed food packaging.

The material provides resistance to grease, moisture and ink migration and can be heat, ultrasonic or thermo sealed. Denmaur's technical information also identifies Delipac grades for microwave, chiller and freezer applications, with ovenable grades tested for temperatures up to 220°C.

Delipac is also certified as recyclable, biodegradable and compostable, with food-contact and migration testing supporting its use in demanding food-packaging environments.

This combination of structural board and barrier performance opens up applications where moving away from plastic would otherwise be difficult.

Grease resistance may be the critical requirement

Some food packaging applications require grease resistance without the broader performance characteristics of a specialist product such as Delipac.

Formakote White GR is a grease-resistant coated board designed for food-service applications. It has a clean white interior, a light-coated reverse to improve printability and is suitable for chiller and freezer use.

The board is available in 400, 450 and 500 micron through Denmaur's Reel Fast service and is manufactured using FSC® certified and traceable pulp sources.

Matching the level of barrier performance to the application helps avoid over-specifying the packaging while still providing the protection the product requires.

Kraft board provides strength with a natural appearance

Kraft carton board can provide another paper-based packaging option where strength, stiffness and a natural appearance are priorities.

Denmaur's Kraftpak is an uncoated, unbleached natural kraft board with high bulk and stiffness. It is certified for direct food contact and suitable for chiller and freezer packaging.

Its combination of strength and appearance makes kraft board suitable for applications where the packaging itself forms part of the visual presentation of the product.

Other kraft grades within Denmaur's range provide different combinations of printability, stiffness, surface finish and food-contact suitability, allowing the specification to be matched more closely to the finished pack.

Consider the structure of the finished pack

Replacing plastic packaging involves more than finding a paper or board with similar dimensions.

Paperboard behaves differently during cutting, creasing, folding and forming. Caliper, grammage, fibre composition, grain direction and stiffness all influence how the finished pack performs.

A board that is too light may lack the rigidity required to protect the product. A specification that is heavier than necessary increases material use, weight and potentially cost.

The aim is to find the appropriate balance between:

Grammage

Caliper

Bulk

Stiffness

Strength

Fold and crease performance

Barrier properties

Printability

Material efficiency

Samples, dummies and production trials can be valuable before committing to a new packaging specification, particularly where an existing plastic format is being redesigned around paperboard.

Food-contact packaging requires additional checks

Where paper or board will come into direct contact with food, the specification must take account of the relevant food-contact requirements.

The intended use matters. Packaging for dry food will have different requirements from packaging exposed to grease, moisture, freezing, chilling, microwaving or conventional oven temperatures.

For example, Denmaur's Delipac range carries certifications and testing covering areas including food contact, migration, grease resistance and specific temperature applications. Kraftpak is certified for direct food contact, while Formakote White GR is designed for food-service applications.

Technical data should therefore be reviewed against the actual conditions in which the packaging will be filled, stored, transported, heated and used.

Recyclability should be considered at specification stage

Moving from plastic to a fibre-based material creates an opportunity to consider what happens to the packaging after use.

The recyclability of the finished pack should be assessed alongside its performance during use.

Ask:

Can the finished packaging enter established paper and board recycling streams?

What barrier technology is being used?

Will food contamination affect disposal?

Are all the components necessary?

Can the pack be made simpler?

Is clear disposal guidance required for the end user?

Delipac is specifically designed as a plastic-free, recyclable barrier packaging board, demonstrating how barrier performance and end-of-life considerations can be addressed together.

Considering end-of-life at the beginning of the design process can prevent a technically successful material change from creating unnecessary complexity after the pack has been used.

Fibre sourcing and certification still matter

Replacing plastic with paper or board also brings fibre sourcing into the specification.

FSC® and PEFC Chain of Custody systems provide recognised methods of tracing certified forest-based material through the supply chain.

The appropriate certification will depend on the individual grade and the organisation's sourcing policies.

Denmaur's carton board portfolio includes FSC® and PEFC certified products across its board ranges, with product-specific certification information available when selecting a grade.

Certification, fibre source, recycled content and product traceability can therefore form part of the wider assessment alongside packaging performance.

Recycled board can be suitable for some packaging applications

Recycled fibre also has a role within carton board packaging.

Denmaur's white lined chipboard range is made from recycled materials and is designed for applications ranging from general carton use to higher-quality packaging. Its Our Revive Greyboard is produced from 100% recycled pulp.

The appropriate fibre composition depends on the application, required appearance, structural performance and any food-contact requirements.

This is another reason to specify packaging around its end use rather than selecting a material on a single environmental measure.

Print quality is part of the specification

Packaging has a practical job to perform, but it also carries the brand.

Colour reproduction, surface smoothness, whiteness, brightness and the appearance of the reverse side can all affect how the finished packaging looks.

For premium packaging, a highly printable GC1, GC2 or solid bleached board may be appropriate. A kraft board can create a deliberately more natural appearance, while specialist barrier boards need to combine functional performance with the required print surface.

Denmaur's carton board range includes grades suitable for packaging where visual presentation is particularly important, including high-end, luxury and graphical applications.

The board should therefore be assessed as both an engineering material and a printed surface.

Sheet size can affect material efficiency

Once a board has been selected, the dimensions of the sheet can have a significant effect on material usage.

Poor fit between the carton layout and the parent sheet can create unnecessary trim and offcuts across a production run.

Bespoke sheeting can help align the supplied board more closely with the dimensions required by the converter.

Denmaur's Reel Fast service provides bespoke carton board sheet sizes, an express sheet conversion service with low minimum order quantities.

Optimising the sheet around the finished packaging can help reduce material use, weight and cost while improving overall yield.

Compare the complete environmental impact

Replacing plastic with paper should form part of a wider assessment of the packaging.

Factors to consider include:

Quantity of material required

Fibre source

Manufacturing

Carbon footprint

Transport

Packaging weight

Production waste

Recyclability

Compostability where relevant and certified

Expected disposal route

Product protection

Risk of damage or spoilage

A packaging material that performs poorly can lead to damaged products, rejected packs or additional production waste.

The strongest specification is therefore one that delivers the required technical performance while supporting the environmental objectives of the project.

Test the board before committing to production

Changing packaging material can affect machinery, print, converting, filling and packing processes.

Before a significant production run, test the proposed board under realistic conditions.

Depending on the application, this may include:

Printing

Cutting and creasing

Folding

Forming

Sealing

Filling

Chilling or freezing

Heating

Transport

Storage

Shelf-life performance

For food packaging, the testing should reflect the actual product and conditions of use.

Denmaur can provide samples, dummies and product cards to help assess potential carton board specifications before production.

FAQs

Can paper completely replace plastic packaging?

Paper and carton board can replace plastic in many packaging applications, but suitability depends on the function of the pack. Strength, moisture, grease, temperature, sealing and food-contact requirements should all be assessed before changing materials.

What types of packaging can be made from carton board?

Depending on the grade and required performance, carton board can be used for folding cartons, food cartons, trays, sleeves, punnets, cups and other formed packaging formats.

Can paper packaging be grease resistant?

Yes. Specialist barrier boards can provide grease resistance for food and food-service applications. Denmaur supplies grades including Formakote White GR and Delipac with grease-resistant properties.

Can paper-based packaging be used in a freezer?

Certain carton board grades are designed for chiller and freezer applications. The exact grade should be selected according to the product, storage conditions and other performance requirements.

Can paper packaging go in a microwave or oven?

Certain specialist barrier boards are designed and tested for these applications. Delipac includes grades suitable for microwave use and ovenable grades tested for conventional oven temperatures up to 220°C.

What is barrier board?

Barrier board is paperboard engineered to provide additional resistance to factors such as grease, moisture or migration. Different barrier boards provide different levels of protection, so the grade needs to be matched to the packaging application.

Is plastic-free barrier board available?

Yes. Denmaur's Delipac range provides plastic and PFAS-free barrier packaging board with grades developed for direct food-contact applications. (Denmaur)

Is kraft board suitable for food packaging?

Certain kraft boards are. Denmaur's Kraftpak, for example, is certified for direct food contact and suitable for chiller and freezer packaging.

How do I choose the right paperboard to replace plastic packaging?

Start with the function of the existing packaging. Identify the required strength, stiffness, barrier performance, food-contact status, temperature resistance, print quality and converting requirements. A paper or board supplier can then help identify grades that meet those requirements.

Choosing a paper-based alternative to plastic packaging

The move from plastic to paper or carton board starts with understanding exactly what the packaging needs to achieve.

Denmaur supplies a broad range of carton board products for food and drink, pharmaceutical, luxury, presentation and general packaging applications, including folding boxboard, barrier board, solid bleached board, kraft carton board, greyboard and white lined chipboard.

Its specialist carton board team can also support customers with product selection, samples, dummies and bespoke conversion through Reel Fast.

For applications requiring specialist food-packaging performance, products including Delipac, Formakote White GR and Kraftpak provide different combinations of barrier performance, strength, stiffness, food-contact suitability and environmental credentials.

To discuss a packaging specification or request samples:

Email: boardsales@denmaur.com

Telephone: 01530 275500