With EU’s Packaging and Packaging Waste Regulation (PPWR) taking effect on 12th August, and the supply volatility of petroleum-based materials, substitution for plastic packaging is picking up momentum, not only for sustainability and compliance reasons, but also for economic and supply chain de-risking purposes. The Interpack packaging show in May of 2026 will undoubtedly accelerate such seismic change.
Plant fiber, with its renewable nature, ease of recycling, and wide supply source, has been one of the leading alternatives to plastic foams. Molded pulp, paper void fill and cushion have already gained popularity over the years. Although paper in the past has not always been seen as a heavy-duty solution, material innovation and the right system changed that. Honeycomb, one of nature’s strongest structures, has been creatively engineered into lightweight paper cushions. The award-winning 3D Honeycomb Mat, a patented structure and process developed by WiAir Corporation, provides a viable paper alternative to a range of plastic foams, while maintaining sound protection.
Some of the attributes of the new honeycomb solutions are:
- Consistent and predictable cushioning: 3D Honeycomb Mat comes in a broad spectrum of cell structures, thicknesses and densities typically associated with plastic foams, ideal for engineered packaging that offers dependable protection.
- Total package optimization: Honeycomb Mat orients its hexagon tubes towards the packaged product, and provides “directional” protection compared to homogenous foams. The light-weight honeycomb packaging offers an opportunity to reduce void space and downsize the total package.
- Versatile, flexible, yet high strength: Besides cushioning, the strong honeycomb structure can handle blocking & bracing for heavy products previously packed with rigid foam or wooden planks, providing high impact absorption.
- Fast and just-in-time (JIT): For customers who depend on an “in-place” and JIT solution, the Honeycomb Mat dispensing system expands the material 30-50 times at the touch of a button. For example, one pallet of Honeycomb Mat can expand up to a truck load of packaging cushions at the time of use.
Foam-in-place packaging delivers a custom-fitted cushion for each product, through a chemical reaction that forms a polyurethane foam, which typically has been for single use. And the mixed-substrate plastics (PU foam adhered to PE film) make the packaging waste problematic to recycle. Is it possible to offer a high-performance cushion made from light-weight paper and delivered just-in-time? Side-by-side drop tests for such common applications as auto parts, industrial machinery, home appliance, arts & crafts etc. yielded comparable protective results - using foam-in-place or Honeycomb Mat packaging. And the material costs are in the ballpark, albeit price points differ by region and have been fluid recently. These findings have been encouraging for users to conduct their own fit-for-use and actual cost comparisons. The holistic cost analysis should include compliance cost and throughout the life cycle, in addition to the cost of material.
Typical applications with 3D Honeycomb Mat paper packaging vs. foam-in-place packaging:
While EU’s PPWR deadline and plastics’ supply volatility have invoked a sense of urgency to seek alternatives to the hard-to-recycle plastic packaging, Extended Producer Responsibility (EPR) and SB54 are reshaping the packaging ecosystem in the US and around the world. Collaborating with partners with complimentary strengthens will help convert paper-based innovations to market leadership, meeting regulatory commitments, while enhancing sustainability – from both environmental and supply resiliency perspectives.