How to Overcome Challenges in Sustainable Flexible Packaging

By Sarah Stieby, Fresh-Lock Marketing Manager

Sustainability has become a driver for change across industries, but it has a particular impact on packaging. In recent years, companies needed to find the right balance between sustainability, product protection, and the consumer experience—something that is often difficult to achieve.

With this continuous rising trend and demand for sustainable packaging, a shift from multi-material packaging to mono-material structures is attainable. Per Smithers, demand for flexible packaging will reach a total global value of $294.1 billion in 2026, up from $248.6 billion in 2021. However, processing challenges were becoming more prevalent when incorporating sustainable materials and practices.

Thanks to new developments in packaging materials and equipment, it’s become easier to produce a sustainable package that includes all of the necessary segments. For example, newer mono-material packaging components are more compatible with each other and can now help optimize converting by sealing at lower temperatures more effectively than earlier versions could.

To achieve sustainable packaging, manufacturers must focus on the entirety of the package rather than individual packaging components. Producing sustainable packaging solutions requires a variety of experts working together; the most successful and innovative projects are the result of collaboration throughout the supply chain. When it comes to packaging, recyclability has dominated the sustainability conversation for many years. In response to consumer demand and growing interest in the circular economy, brand giants such as Coca-Cola, Target, and Walmart have already started moving toward 100%-recyclable packaging.

As the industry continues to prioritize generating less waste from plastics, we can expect consumers and brands alike to opt for recyclable solutions. In fact, a Future Market Insights report on the global packaging industry predicts flexible paper packaging and biodegradable options will be on the rise due to their recyclability. Flexible packaging is also a promising option for the sustainable packaging segment. Due to its reusable, economical, and lightweight attributes, flexible packaging offers a low-energy alternative to rigid packaging and has the potential for a better consumer experience, especially when paired with a reclosable zipper or slider.

Source reduction and reuse, recyclability and compostability, and proper disposal are all key components of fully sustainable packaging options—and flexible packaging can provide all of these solutions.