In the world of food packaging, plastic has been both a hero and a villain. On one hand, it extends shelf life, reduces food waste, and makes packaging lightweight and affordable. On the other, it’s under increasing scrutiny for its environmental impact. For companies developing plastic food packaging materials, walking this fine line comes with a unique set of challenges.
Today we will examine the key food packaging challenges companies must overcome to adopt safe, sustainable and cost-effective plastic solutions.
1. Balancing Food Safety and Sustainability:
Food safety is non-negotiable. Packaging materials must provide protection from moisture exposure and oxygen infiltration while blocking UV light and preventing contaminants. While plastic traditionally performs well in these areas, food packaging challenges arise when companies aim to improve sustainability by sourcing recycled or bio-based materials.
Recycled plastics can vary in quality and bio-based plastics often fail to deliver the same barrier properties found in conventional plastics. To achieve safety standards alongside sustainability targets companies must engage in extensive R&D and obtain regulatory approvals which can slow the pace of innovation.
2. Meeting Stringent Regulatory Standards
Another major food packaging challenge is staying compliant with global regulatory requirements. The EFSA in the EU requires stringent compliance and testing protocols while the U.S. FDA operates under its own distinct regulatory framework. These regulations control both the production chemicals and the acceptable levels of substance migration from packaging to food.
As a result, businesses must frequently adjust their product formulas to remain compliant with increasingly strict regulations regarding substances such as BPA and phthalates. Navigating this evolving regulatory landscape demands time, investment, and expertise.
3. The Push for Recyclability and Circularity
Consumers and governments are demanding packaging designs that prioritize recyclability and circularity. Developing a mono-material packaging solution that meets functional requirements including barrier protection, durability, and flexibility without using multi-layer non-recyclable formulations remains a challenging task.
Multilayer materials deliver superior protection for food products, but are difficult to recycle due to their mixed plastic composition. Businesses need to develop innovative strategies for creating simpler and recyclable packaging designs, which can be difficult and costly to produce at scale.
4. Cost Pressures in a Competitive Market
Adopting sustainable materials and redesigning packaging represents a costly investment for companies. Both bioplastics and advanced recycling technologies come with increased costs compared to traditional plastics. Food manufacturers and retailers show hesitation to take on additional costs.
The continuous challenge for packaging companies lies in maintaining a competitive position while achieving performance standards alongside sustainable practices at reasonable costs.
5. Consumer Perceptions and Expectations
Today's consumers are more informed - and vocal - than ever about sustainability issues & concerns. Consumers prefer packaging that protects the environment without compromising convenience, shelf life, or price. At the same time, there's often confusion around what’s "better": recyclable, compostable, biodegradable, or reusable?
Packaging companies must undertake consumer education campaigns to provide solutions that satisfy increasing expectations in a market where the definition of "sustainable" remains undefined.
Developing plastic materials to meet today's food packaging requirements presents a complex challenge. Businesses need to manage food safety and sustainability alongside regulatory requirements and customer expectations while also keeping expenses low and remaining market competitive.
But with challenges come opportunities. Innovations in materials science together with better recycling technologies and industry partnerships are creating packaging solutions that deliver efficiency and environmental care.
Conclusion: Turning Food Packaging Challenges into Innovation
Modern food packaging requires more than functionality—it must also meet growing sustainability standards, regulatory requirements, and consumer expectations, all within cost constraints.
But with challenges come opportunities. Advances in materials science, improved recycling technologies, and strategic industry partnerships are helping companies overcome key food packaging challenges while delivering solutions that balance performance and environmental responsibility.
