Could Fibre-Base Packaging Replace Plastic?

Renata Daudt
Oct 6
5 min read

Updated: Oct 13

Earlier this month, at the Functional Fibre Based Materials and Packaging Conference held in Valencia, Spain, on October 1–2, I had the opportunity to speak about ANZ regulatory landscape and hear from researchers, chemical companies, papermakers and brand owners driving the shift toward fibre-based packaging. The discussions revealed not only how fast this transition is happening, but also the complexity behind replacing plastics while maintaining functionality and compliance.

With the Packaging and Packaging Waste Regulation (PPWR) requiring all packaging to be recyclable by 2030, alongside new rules such as mandatory recycled content for plastics and the Plastic Tax, the packaging industry is undergoing a major transformation.

The search for sustainable alternatives is intensifying, and paper-based packaging is emerging as one of the most promising solutions. But as we move away from polymers, one key question remains:

Can paper truly replace plastic while maintaining the barrier properties required by today’s packaging?

regulations Changing the packaging Landscape

Flexible packaging—of which a significant share is used for food applications—is transitioning rapidly toward fibre-based formats.

Under the PPWR, packaging can still contain up to 5% plastic by mass and be considered recyclable (as long as it achieves at least 70% recyclability). However, the Single-Use Plastics (SUP) Directive sets a stricter boundary: it only accepts natural polymers not chemically modified by humans.

Here’s how it defines “plastic”:

“Plastic means a material consisting of a polymer as defined in Article 3(5) of Regulation (EC) No 1907/2006 (REACH), to which additives or other substances may have been added, and which can function as a main structural component of final products, except for natural polymers that have not been chemically modified.” — Single-Use Plastics Directive (EU) 2019/904

In practice, this means that many coatings traditionally used to provide essential barriers (against moisture, grease, and oxygen) could still render a package “plastic” under SUPD. The table below exemplifies what is considered plastic barriers.

The Race for Plastic-Free Barriers

As policies reshape the packaging landscape, the industry is pushing hard to develop new-generation coatings that deliver the same performance as plastics— without containing any.

At the conference in Valencia, several companies presented groundbreaking solutions:

Lamberti introduced a Tomato Skin Barrier Coating, derived from natural agricultural residues.
Xampla presented Morro, a protein-based coating made entirely from plants.
Qwarzo showcased a mineral-based coating, extracting silica from plants—fully plastic-free and exempt from the Plastic Tax.

From global chemical companies like Dow to smaller innovators such as Xampla, Qwarzo, and Lamberti, their R&D efforts are converging on one goal: plastic-free, high-performance barrier coatings for fibre-based packaging.

Venture Capital as Emeral has shown interest in these technologies which underscores their long-term potential and strategic importance. This is a technology that is developed to stay and there's a huge new market for them.

Researchers from LUT University, ITENE, and Graphic Packaging International presented multiple case studies evaluating barrier performance, recyclability, and regulatory compliance. Food packaging is in focus as the category with higher growth potential and strict regulations.

Testing partners such as Mérieux NutriSciences play a critical role in assessing migration, barrier integrity, and PFAS content for brands and packaging suppliers supporting with the mandatory Declaration of Compliance as growing concern across Europe.

Adding PFAS intentionally is already restricted, but even trace migration poses challenges. Studies have shown that PFAS can move through composting systems, underlining the need for materials that are not only functional but safe and compliant.

By August 2026, all food-contact packaging in the EU must meet the following PFAS limit values:

25 ppb for any individual PFAS (targeted analysis)
250 ppb for the sum of PFAS after degradation of precursors (where applicable)
50 ppm for total PFASs (including polymeric PFAS), where total fluorine exceeds 50 mg/kg

Industry Perspectives and Market Insights

After I presented about ANZ Packaging Regulation Overview I joined the panel discussion with Bernhard from Dow, Kalle from AFRY and Michele from Perfetti van Melle (owner of Mentos, Trident, Chupa Chups). The discussion focused on the PPWR and global packaging regulations, and there was broad agreement that there’s still a great deal of work ahead. Many brands are adopting a wait-and-see approach until the European Commission releases the recyclability grading system expected by 2027, along with the harmonised recycling labels. However, large players like Nestlé can’t afford to wait—implementing packaging changes typically takes two to three years, from research to rollout. The added complexity of sourcing recycled content in Europe and ensuring traceability only makes this transition more challenging.

AFRY shared valuable data and forecasts, providing the numbers everyone in the room wanted to know, further reinforcing the momentum behind fibre-based packaging.

Brand owners are also adapting. In my discussion with Nestlé UK team attending to the conference, it became clear that navigating Extended Producer Responsibility (EPR) in the UK requires tailored, case-by-case solutions. For some products, paying the Plastic Tax may still be more cost-effective than changing packaging materials entirely.

The Rise of dry Moulded Fibre

One of the most exciting developments in the fibre packaging space is the growth of dry moulded fibre (MF) solutions for food, pharmaceuticals, and even cosmetics. The swedish company Pulpac leads the way in the technology for dry moulded fibre and works with PA Consulting to develop new solutions for the industry. Let me know if you're interested and I can make an introduction.

AFRY also outlined the key factors that make moulded fibre a highly promising material for the future.

Recent innovations include:

Pharma blister packs by PA Consulting
Coffee capsules from Capsul'in PRO
Cosmetic packaging applications replacing rigid plastics
Food and beverage packaging including closures.

Unlike paper sheets, moulded fibre has distinct fibre bonding characteristics, requiring specialized coatings to enhance moisture, vapor, and oxygen barriers.

Solenis has presented their latest development dedicated chemical systems for MF and presented comparative case studies demonstrating how the right coating can significantly improve barrier performance and sustainability.

A New Chapter for Packaging

The takeaway from Valencia was clear: the shift from plastic to paper is well underway, but it’s not a simple swap. It’s an ongoing process of material innovation, regulatory adaptation, and system redesign.

While technical challenges remain—particularly in achieving barrier functionality without compromising recyclability—the progress showcased at the conference proves that nature-inspired, fibre-based packaging is not just a vision for the future. It’s already here—and it’s evolving fast. If you want to learn how can we help you with this transition check our services or book a call.

On the Shelves of Valencia

On my first day in Valencia, I did what I always do when I arrive in a new city—I headed straight to the supermarket. It’s one of the best places to spot packaging trends in real life. Among the aisles of fresh produce, paper-based packagingfor fruits and vegetables immediately stood out. Many packs carried bold messages about plastic content and its impact on nature, a clear reflection of how sustainability is being communicated directly to consumers.

As I browsed, I noticed that Spain has its own mandatory recycling label, a system that tells consumers exactly which bin colour each package belongs to. The label not only spells out the colour name but is sometimes printed in the corresponding colour—a small but clever detail that makes sorting more intuitive.

For global brands like Pringles, though, the reality is more complicated. Their cans now feature three different recycling logos—one for France, one for the UK, and one for Spain—all squeezed onto the same pack. Until the European Commission finalises a harmonised recycling label across the EU, this kind of on-pack clutter will continue to illustrate just how fragmented recycling communication still is across Europe.