It’s official. We’re living in the era of the circular economy. This economic model aims at reducing waste by minimizing the amount of resources used.
The Environmental Protection Agency (EPA) describes it as an economy where materials/products are kept in circulation as long as possible. For resources to retain their highest value for the longest time, they must be non-toxic and biodegradable.
The packaging industry, particularly that dedicated to food packaging, can contribute immensely to a circular economy. After all, it is expected to reach a market value of $512 billion by 2028. However, first, we need to look at the different faces of unsustainability in this area. This article will discuss unsustainable food packaging along with ways to choose better alternatives.
The Risk of Unsustainable Packaging in the Food & Beverages Industry
Unsustainable food packaging will have certain characteristics. Most importantly, the materials will be non-biodegradable, non-reusable, and non-recyclable. A major example that comes to mind is single-use plastic. It refers to disposable plastic that is designed to be used once and then tossed or discarded.
A good portion of food products to date still arrive in single-use plastic containers. It was found that even in 2024, the US government had failed to implement an effective plan that reduced the usage of single-use plastics.
Besides bioaccumulation, single-use plastic packaging carries health risks to humans. Such food packages may contain a film of harmful chemicals called per- and polyfluoroalkyl substances or PFAS.
The Same Chemicals That Injured Firefighters
A lot of folks are still unaware of PFAS and their health repercussions. Sharing an almost unbreakable carbon-fluorine bond, these chemicals are also used to coat non-stick cookware.
What’s shocking to note is that they have been used to manufacture Class B firefighting foam or Aqueous Film-Forming Foam (AFFF) for decades. Direct exposure to them caused serious injuries in the form of testicle, bladder, and kidney cancers.
Injured firefighters and military servicemen have filed litigation against PFAS manufacturers like 3M. Under the AFFF lawsuit, Navy veterans have alleged that despite being aware of the risks, PFAS manufacturers failed to take measures to inform/warn.
According to TruLaw, over 10,000 personal injury cases have been reported for which Bellwether trials will be held in 2025. Such chemicals are used in food packaging to keep the food inside from sticking to the container.
Also, the chemicals create a barrier that prevents water and grease from soaking through the packaging. This may look like a valid use but PFAS can easily migrate from the packaging to the food. Upon consumption, the food may cause liver damage, thyroid disease, cancer, or hormone suppression.
3 Ways to Replace Unsustainable Food Packaging With Better Alternatives
The need of the hour is to make food packaging as sustainable as possible. This is especially needed since a collective PFAS ban has been proposed by countries worldwide. Let’s look at three ways to choose better alternatives.
Reduce Packaging Waste
A huge part of becoming sustainable is reducing the amount of waste that is generated. This helps conserve natural resources and reduces the environmental impact of waste disposal.
Packaging companies need to start with a packaging design that is minimalistic and uses fewer materials. Complex designs may require multiple (unnecessary) layers of packaging that increase plastic waste generation.
Also, smart packaging or wrapping techniques can be used to reduce the packaging size. This helps in bringing down transportation costs. Finally, reusable containers can also help reduce the amount of waste generated.
Choose Non-Toxic Materials
Simply choosing packaging materials that last a long time or can be recycled is not enough. We want the food to be safe and free from any undesirable chemicals like PFAS. The Food and Drug Administration (FDA) announced in 2024 that grease-proofing substances that contain PFAS would no longer be available for contact use in the US. This means it’s time to look for safer packaging alternatives.
Glass is a good option, but may not be suitable for transporting food items over long distances. Other alternatives include paperboard, silicone, foam-insulated food bags, and hemp boxes.
Optimize the Supply Chain
One of the most foolproof ways to go sustainable with food packaging is to optimize the entire supply chain itself. This process will include the packaging material selection and design, and extending far beyond these.
For instance, a company may incorporate smart packaging features like time and temperature indicators to monitor food quality and determine product dating. Similarly, it can partner or collaborate with suppliers who also practice sustainability in their operations.
Another way to make the entire process of food packaging sustainable is to reduce carbon emissions. Transportation routes can be chosen accordingly. Closed loop systems can be established where the packaging is collected, reused, and recycled.
According to a 2025 consumer report, 54% of those surveyed reported purchasing products with sustainable packaging. Consumers are even willing to pay more to show their support for sustainable brands.
The time to go sustainable is now or never, not just for business but also for the environment. In the coming days, such brands will stand apart as solid examples of commitment to customer safety and environmental protection.
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Rick LeBlanc, EMBA, is the founder and editor of Reusable Packaging News (subscribe to the free newsletter) and editor of Western Pallet Magazine. A supply chain journalist with more than 30 years of experience, he specializes in pallets, reusable packaging, material handling and related operations. Rick is co-author of Pallets: A North American Perspective and Pallets & Progress: A Collected History of Pallets and Palletized Handling 1922–1945. He is also an advisory board member of the Virginia Tech Center for Packaging and Unit Load Design. Read Rick’s full bio.
