Sappi explores the evolution of specialty packaging paper, examining the intersection of sustainability, innovation, and new industrial challenges. The shift from plastic to functional paper presents both technical and market hurdles — but it is an essential path for the future
by Massimiliano Luce
Packaging has undergone profound transformations in recent years. While plastic once seemed like the perfect solution to ensure strength, impermeability, and long shelf life, its environmental impact has made the need for more sustainable alternatives increasingly clear. But is it really possible to replace plastic with materials that offer comparable performance and recyclability? Paper might be the answer, but the transition is far from simple. Behind seemingly ordinary packaging lies a world of research, innovation, and technical challenges.
The paper industry amid change and challenges
“The paper sector is experiencing a particularly pivotal moment,” says Simone Vezzù, Manager of the Competence Center for Digital & Liner Solutions at Sappi. While graphic paper is in decline, the demand for specialty packaging papers is on the rise, driven by the need for more sustainable solutions. As a result, paper mills are pursuing two main development paths. On one hand, there’s the challenge of converting part of their graphic paper production lines to manufacture more market-demanded materials such as specialty papers, paperboard, and cartonboard. “This is not an easy transition, as machinery used for graphic paper differs significantly in configuration from that used for packaging paper,” Vezzù points out. However, market pressures are pushing in this direction, and companies must adapt quickly to remain competitive.
On the other hand, there’s the challenge of developing advanced paper-based solutions for the packaging of the future that can replace plastic. Innovation can take place either directly within paper mills or through the many paper converters present across various regions.
The demands of flexible packaging
“A paper-based package must ensure mechanical integrity, protection from external agents, and printability,” explains Vezzù. In today’s market, packaging paper is rarely used alone. It is typically combined with other materials—such as plastic films or aluminum layers—to achieve the necessary barrier properties. The industry’s challenge is to reduce the amount of added materials while improving sustainability and recyclability.
Flexible packaging is one of the most promising areas for functional paper. This segment includes products for the food, cosmetic, and pharmaceutical industries, where protecting the contents is critical. “We’re seeing more and more hybrid solutions, where paper is treated with special coatings to improve barrier properties without compromising recyclability,” Vezzù adds.
Innovative solutions for functional paper
To enhance the performance of packaging paper, the industry employs several technologies: lamination, extrusion, and advanced surface treatments. “The goal,” Vezzù emphasizes, “is to minimize the amount of added material while maintaining high performance.” However, papers functionalized with thin coatings present challenges, particularly in achieving compact protective layers and maintaining gas permeability.
One of the main hurdles is compatibility with existing packaging machinery. “These machines are designed to work with plastic materials, which have very different mechanical properties from paper,” Vezzù explains. For this reason, paper producers are collaborating with machine manufacturers to develop solutions compatible with current industrial technologies.
Another key focus is research into alternative materials. “One of the future goals for the paper industry is to develop papers that not only reduce plastic content but are also made from renewable and recycled fibers without compromising quality,” Vezzù notes. This also means exploring non-wood plant fibers, such as hemp or bamboo, and improving the recovery of post-consumer fibers.
Sappi’s path toward sustainability
Sappi began developing functional papers more than a decade ago and now offers solutions that reduce plastic use in packaging compared to traditional paper-based materials using lamination or extrusion technologies. “To replace plastic,” says Vezzù, “we need to improve the mechanical properties of paper and make it compatible with existing packaging lines, especially in applications where plastic film is being replaced.” This requires joint efforts from paper manufacturers, converters, and brand owners.
Another crucial aspect is the use of renewable raw materials. “Our packaging papers are made exclusively from virgin fibers sourced from sustainably managed forests, ensuring environmental protection while supporting the circular economy,” Vezzù states.
From market to future outlook
The large-scale adoption of functional packaging papers will depend on the industry’s ability to enhance their performance. “Today, almost all commercial barrier layers are fossil-based,” Vezzù concludes, “but the future lies in gradually reducing plastic and using raw materials from natural sources.”
The challenge is on, and the paper industry must continue to innovate to provide ever more sustainable and efficient solutions. Innovations in the sector are already yielding concrete results. Many brands are testing new materials to replace plastic packaging with paper-based alternatives, and some have already introduced recyclable products to the market. “The next step will be to further improve the mechanical properties of paper and develop biodegradable barriers that can fully replace traditional polymers,” says Vezzù.
The future of sustainable packaging is still unfolding, but the direction is clear: less plastic, more paper, and greater environmental awareness.