Aptar Beauty launches recyclable wine bottles made of rPET, reducing weight and carbon emissions.
In 2025, the plastic packaging industry is set for a pivotal transformation. On one hand, regulatory frameworks such as the EU's Packaging and Packaging Waste Regulation (PPWR) are being introduced, encouraging the reduction of packaging waste and enhancing recycling efforts. On the other hand, the burgeoning health supplement and ready-made meal markets as well as pet economy are driving new demands for innovative, and experience-driven plastic packaging.
Within this landscape, sustainable packaging, functional packaging, ready-made meal packaging and pet food packaging emerge as key focus areas for the plastic packaging supply chain.
Evolution of green packaging
Due to rising costs of recycled plastics and supply instability, major consumer goods companies such as Unilever, Colgate, and Coca-Cola have revised their sustainability goals for 2025 and 2030 as of 2024. Despite these adjustments, reducing carbon emissions and enhancing sustainability remain essential strategies for achieving carbon reduction targets.
Increase in recycled plastics adoption
The drive for sustainable packaging has spurred greater adoption of recycled materials. For example, Coca-Cola expands its use of 100% rPET bottles from Canada, the Philippines, and Myanmar to Hong Kong (China) and India. ALPLA supplies recyclable wine bottles made from rPET for Austria's Wegenstein winery; these bottles weigh only one-ninth of their glass counterparts, significantly reducing carbon emissions.
Besides, Aptar Beauty has introduced the Color Code PCR plastic perfume pump, which contains up to 67% post-consumer recycled (PCR) resin. This innovation not only reduces carbon emissions by 39% but also allows for color customization. Furthermore, NEOS Styrolution has successfully completed its first mechanical recycling project for yogurt cups made from PS.
Diversification of bio-based materials
Bio-based plastics are gaining traction in packaging across various sectors, including food, beauty, and pharmaceuticals, utilizing raw materials such as waste cooking oil, plants, and carbon dioxide.
Recently, companies like Lamb Weston, Suntory, Viscofan, and Pigeon have launched packaging solutions like chip packaging (bio-based PE), beverage bottles (bio-based PET), sausage casings (bio-based PA), and baby bottle caps (bio-based PP) made from waste cooking oil. These bio-based plastic packages not only meet essential barrier requirements and safety certifications but also achieve a carbon reduction of 60% to 70%.
Cosmetics brand Dior plans to incorporate plant-based polyethylene furanoate (PEF) from Avantium, a Dutch renewable chemicals innovator, in its primary packaging, making it the first cosmetics brand to utilize 100% plant-based materials in this aspect.
Additionally, pharmaceutical packaging and medical device manufacturer Bormioli Pharma has partnered with the Italian pharmaceutical group Chiesi to supply PET plastic bottles created with carbon capture technology. This process captures carbon dioxide and converts it into bioethanol through fermentation, which is then used to produce PET. These plastic bottles will be used for packaging medicines related to rhinitis treatment. This marks the first implementation of carbon-captured PET bottles in pharmaceutical packaging.
Penetration of reusable and refillable packaging
Reports indicate that only 9% of global plastic waste is recycled, with recycling rates varying significantly by location, plastic type, and usage. However, adopting a "reusable and refillable" design can extend the lifespan of plastic packages and reduce their entry into waste streams. This approach is crucial for mitigating plastic pollution and serves as a strong complement to enhancing plastic recycling.
Designing reusable and refillable packaging presents practical challenges, requiring collaboration among manufacturers, retailers, service providers, and policymakers. Despite these difficulties, some companies are eager to lead the way.
For instance, Chinese cosmetics brand Proya has upgraded its flagship products with a “vacuum-sealed dual-chamber + refill” design, with each refill reducing plastic usage by over 100 grams. International brands such as Shiseido, Guerlain, and Chanel have also introduced refillable designs in their high-end skincare lines, providing consumers with cost-effective options while minimizing plastic use.
Refillable packaging is beginning to penetrate into broader markets beyond high-end products, with more products likely to adopt refillable features as standard.
Rise of functional packaging
In addition to the evolution of sustainable packaging and the booming health supplement market in recent years, functional packaging is on the rise. As the post-90s and post-00s generations become the primary consumers, health supplement products are increasingly trending towards snack-like and ready-made meals formats. Packaging must not only provide high barrier properties for freshness and quality preservation but also incorporate personalized elements and interactive designs to cater to young consumers' needs.
BA.LAB's instant/ready-to-eat probiotics packaging is inspired by the Nintendo GBP handheld gaming console, utilizing a sugarcane pulp molding process to create unique packaging. The portable inner bag mimics a game cartridge, integrating brand information with a game progress bar. This lightweight, pocket-sized packaging is eco-friendly, youthful, stylish, and convenient compared to similar products.
CheongKwanJang's vitality supplement gift box features a dual-dosage packaging design, allowing consumers to take both liquid and tablet forms simultaneously. Its structural design also facilitates the separation of metal and plastic lids.
The health supplement sector is expected to continue infusing new ideas into packaging, fostering a deep integration of products and packaging solutions.
Upgrades in ready-made meals packaging
The post-90s and post-00s generations prioritize not only health but also an efficient lifestyle. Ready-made meals effectively address the cooking challenges faced by young people. Diverse consumption scenarios like outdoor camping further enhance the popularity of these meals.
Market research indicates that the Chinese ready-made meal market continued its rapid growth in 2024, with the market size projected to exceed RMB 560 billion.
As the market evolves, packaging innovation has become essential for brand differentiation. From materials and structures to visual design, the packaging of ready-made meals is advancing towards higher functionality and personalization.
Amcor's microwave automatic venting bag employs a four-layer packaging structure and nitrogen-locking technology to preserve the fresh flavor of food. This bag can be heated directly in the microwave and features a stand-up design, truly embodying the concept of “the bag is the bowl,” offering convenience to consumers.
Sealed Air's anti-fog cover film for salads is tailored for retail packaging, including salad boxes and fruit and vegetable trays. This film maintains transparency while providing effective sealed protection.
Chengdu Qinhuan Technology specializes in antimicrobial materials and has developed a new type of inorganic non-metal antibacterial material for ready-made meal packaging. This innovative material effectively inhibits the growth of bacteria and mold, extending the shelf life of food while ensuring safety and non-toxicity.
High barrier and smart pet food packaging
Pet products are increasingly popular among young consumers, driving the growth of the pet economy. The pet food market, in particular, is thriving, which is propelling the pet food packaging sector. According to Deep Insight Research, global sales of pet food packaging were approximately RMB 50.06 billion in 2023, projected to reach RMB 67.48 billion by 2030, with a CAGR of 4.36% from 2023 to 2030.
Pet food packaging must offer superior freshness and moisture-proof features while also prioritizing portability and ease of feeding. As a result, packaging often employs high barrier materials or nanomaterials with specialized antibacterial technology, along with coatings designed for quality preservation. Many packages also integrate smart devices for interactive feeding.
For example, Canadian pet food brand Fable utilizes a special plastic material for its dog food packaging, incorporating a smart chip sensor that monitors oxygen and humidity levels inside. This alerts pet owners about the freshness of food through color changes in indicator lights.
Sustainability is also becoming a focus in pet food packaging. Pedigree's dental chew products feature recyclable PE for mono-material packaging, while some Mars Petcare products incorporate up to 60% recycled plastic. The broader application of mono-material designs and recycled plastics will further enhance sustainability in pet food packaging.
From sustainable and functional packaging to innovations in pet food packaging, these developments demonstrate the plastic packaging industry's proactive adaptation to regulations and market changes. Moving forward, the industry is expected to deepen its efforts, achieving a win-win scenario of economic value and environmental benefits.
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