Case Study • Sustainable Packaging
How End Users & OEMs Are Building a More Sustainable Packaging Future
Drawing on PMMI custom research and field interviews, this case study shows how CPG teams and OEM partners are transitioning materials, adapting equipment, and improving outcomes—without sacrificing performance.
Background: Why Collaboration Beats Compromise
End users face SKU growth, retailer requirements, and evolving legislation—while still protecting product quality and throughput. OEMs are redesigning or modifying machinery to run recyclable and PCR materials more reliably, and to maintain uptime across variable substrates.
The Challenge: Real Trade-Offs, Real Decisions
Most brands report trade-offs when adopting sustainable packaging—especially costs and performance. OEMs, meanwhile, must balance flexibility with process capability as recycled content and new substrates introduce variability.
- Costs increase as materials and changeovers evolve.
- Performance risks (seal quality, shelf life, product protection) require testing.
- Legacy machinery can constrain change without targeted upgrades.
Approach: A Three-Step Collaboration Model
1) Joint OEM–CPG Line Testing
Run structured trials on recyclable films/corrugate to tune sealing windows, film tension, and guide rails; document run rules for each SKU/material.
2) Targeted Machine Enhancements
Retrofit servo controls and quick-change tooling to accommodate variable thickness or recycled content; add tolerance in handling systems for board variability.
3) Sensor-Driven Monitoring
Instrument critical points (temperature, seal pressure, film stretch) and alert operators when values drift; use dashboards to shorten troubleshooting and reduce waste.
Outcomes: What Good Looks Like
| Material Trend (2025 → 2030) | % Planning Transition | Primary Drivers |
|---|---|---|
| Polystyrene (PS) | 70% replace | Retail restrictions, consumer pressure |
| Foams | 46% replace | Sustainability initiatives |
| PVC | 38% replace | Regulation and material alternatives |
| Recycled paperboard (FSC) | 91% retain | High availability and low cost |
Results reflect a composite of interview patterns and machine-modification best practices; your mileage will vary based on product, format, materials, and line design.
Where Materials Are Headed (3–5 Years)
Industry data indicates momentum toward recyclable substrates (e.g., recycled paperboard with forestry certification, corrugate) and away from polystyrene, foams, and PVC. Pair your roadmaps with retailer guidelines and state/regional policy to prioritize the biggest wins first.
- Likely retained: recycled paperboard & certified corrugate.
- Likely replaced: polystyrene (PS), foams, PVC.
- Still emerging: reuse & compostables (infrastructure-dependent).
Implementation Playbook
- Map SKUs & materials; rank by volume, risk, and compliance pressure.
- Choose 1–2 “pilot” formats for joint OEM testing; lock run rules.
- Retrofit for tolerance (servo, web handling, QA checks); document SOPs.
- Instrument the line; trend alarms on seal quality and reject codes.
- Scale to adjacent SKUs; update training and changeover standards.
See It, Compare It, Validate It
End users and suppliers often explore real-world solutions through PMMI’s Portfolio of Trade Shows— uniting packaging and processing professionals to discover new technologies, materials, and best practices that drive manufacturing innovation.
