The ultimate guide to food packaging: sustainability issues and solutions

Explore the issues with single-use plastic food packaging and discover the inspiring people developing sustainable solutions

17 Dec 2024

7 min reading time

As a child, Lucy Hughes fell in love with the ocean. Going diving with her family from the age of 12, she felt at home beneath the waves. But as time went by, Lucy saw the marine environment become increasingly polluted by plastics and other waste. Determined to do something about it, she joined a product design course – and committed to an eco-friendly approach. Today, Lucy is the founder and CEO of MarinaTex, an award-winning startup developing alternative food packaging made from seafood waste and algae.

In this article we explore the issues with existing food packaging. And we highlight inspiring people and businesses developing sustainable, green packaging options.

The problem with single-use plastic food packaging

The issues with plastic are well documented. Plastic is the most common packaging material in the world, particularly polyethylene because of its low price, robustness and versatility (1). In the food sector, these materials – often containers, wraps, or other protective packaging – are undeniably convenient and help preserve products. But plastic waste brings pervasive environmental costs and the food industry is a major contributor (2).

Much of this waste ends up in landfills, where it can persist for centuries. Nearly half of all plastics are manufactured for single-use purposes, and vast quantities end up in the environment, waterways, and oceans – 245,000 tonnes annually (3). Plastic production also accounts for 3.4% of global greenhouse gas emissions throughout its lifecycle, thereby exacerbating climate change (4).

Worldwide, approximately 150 million tonnes of plastic are used annually for packaging, with 37 million tonnes dedicated to food packaging across agricultural value chains (5,6). In Europe, the average person generates nearly 180 kg of packaging waste per year (food and non-food), a figure that has risen by over 20% in the past decade (7). This trend highlights the urgent need for resource conservation and waste reduction strategies, along with increased efficiency in material use and recycling processes. If left unchecked, plastic waste across the EU will increase by 46% by 2030 (8).

The impact of packaging on human health

Most plastic is good at its job. Robust packaging protects food from contaminants during transport and storage, reducing spoilage and thereby reducing food waste. But not all packaging is harmless. Food contact materials (FCMs), particularly plastics, can leach harmful chemicals into food, which can be carcinogenic (9).

Microplastics and nanoplastics present additional challenges. These tiny fragments, often originating from packaging, accumulate in oceans and infiltrate food chains, potentially harming marine life and humans. By 2050, plastic particles in the ocean are expected to outnumber fish (3). Annually, humans consume an estimated 70,000 to 120,000 microplastic particles, primarily through air, food, and drink. Those relying on bottled water may ingest an additional 90,000 particles per year (10).

By 2050, plastic particles in the ocean are expected to outnumber fish

- Ghasemlou et al. (3)

Furthermore, Bisphenol A (BPA), a synthetic chemical used in plastic and metal containers, exceeds acceptable safety levels in many individuals. A recent EU biomonitoring study found up to 100% of participants in 11 countries had BPA exposure beyond health thresholds, posing significant risks (10).

The ‘no packaging’ movement and demand for plastic alternatives

Consumers are increasingly rejecting single-use plastic food packaging as they learn of the issues – instead favouring brands offering natural, durable, refillable containers and alternatives such as glass, jute and other biodegradable materials (11). A 2022 survey by the EIT Food Consumer Observatory identified particular frustration with overwrapping and redundant packaging (12). “Cucumbers that are shrink-wrapped. It's just silly and annoying to remove,” said one UK respondent. Another participant from France said: “I am really happy to choose more and more brands that make the effort to use a minimal amount of packaging.”

'Cucumbers that are shrink-wrapped. It's just silly and annoying to remove.'

- UK participant, EIT Food Consumer Observatory study (12)

To tackle packaging waste, we need more circular economies, and to adopt the 4R approach – reduce, reuse, recycle, redesign (5). The movement embraces practical steps, like selling grains, nuts, and fruits unpackaged or reducing packaging by offering larger portions instead of smaller, individually wrapped items. Local production and consumption further minimise packaging needs by reducing transport and storage requirements (5).

Paper bags and cardboard boxes provide a more sustainable option in some cases. But their production contributes to deforestation, consumes significant energy and water, and generates waste (13). Alternatives are needed, and consumers seem open to new ideas. Plastic-free packaging was rated as the sustainability innovation area with the highest adoption potential (78%) in a 2021 Consumer Observatory study (14).

Peakbridge VC has identified four key areas in which startups are developing products: Bioplastics; Edible Packaging; Smart Packaging; and Reusable Packaging (15).

Six startups to watch in the sustainable packaging sector

Here are six exciting startups to recently join EIT Food’s Entrepreneurship programmes:

1. Notpla (UK) – since launching in 2014, the company has replaced 16 million single-use plastic items across Europe and aims to raise this to over 100 million units annually within two years. Compass Group, Decathlon, and Just Eat are among the corporations using Notpla’s seaweed-based containers and food packaging solutions, and a recent funding round of US $25 million will help Notpla break into the US market.

2. Blue Ocean Closure (Sweden) – Plastic bottle caps are a major contributor of plastic pollution in our oceans, and marine animals often mistake these caps for food. Blue Ocean Closure has devised an alternative option – closures from highly pressed natural fibers.

3. Bio2Coat (Spain) – Wouldn’t it be cool if you could just eat the packaging? That’s the idea with Bio2Coat’s 100% natural edible coating tailored to extend the shelf life of perishable foodstuffs such as fruits and vegetables, without changing the taste, appearance or smell of the products.

4. ZeroImpack (Italy) – Single-use packaging could be eliminated entirely from school canteens, university campuses and corporate offices thanks to Zero Impack. They are pioneering reusable packaging as a service, and their impact could be huge once adopted by industry players like Sodexo.

5. MarinaTex (UK) – as described at the start of this article, Lucy Hughes founded MarinaTex to tackle the issue of marine plastics pollution. Her startup’s films and coatings are derived from seafood waste and red algae that are compostable, effective, and food safe, while recyclable in paper streams.

6. Pack2Earth (Spain) – as passionate trail runners and hikers, Pack2Earth’s founders were appalled to discover that countless empty sports nutrition packets discarded in nature. They have developed bio-based films from plants and minerals that are robust and flexible, while compostable at ambient temperature.

Several of these startups are part of EIT Food's accelerator network focused on innovations and solutions for sustainable packaging. They will have access to corporates and food companies within the programme, including beer brands like Hijos de Rivera and EFES, and food companies such as Paulig, General Mills, and Sodexo.

Apply to join the EIT Food Accelerator Network

Roadmap to a sustainable future in food packaging

We are starting to see broader change throughout the food system. Major companies are recognising that sustainable packaging plays a crucial role in carbon footprint reduction and mitigating the environmental impact of the food industry.

Over 500 companies, producing 20% of the world’s plastic packaging, have committed to 100% recycled, recyclable, or reusable materials through the New Plastics Economy Global Commitment. PepsiCo – one of the signatories – aims to cut virgin plastic from non-renewable sources per serving across its global beverages and convenient foods portfolio 50% by 2030.

But more collaborative action is needed, and we need to acknowledge the challenges. Right now, producing biodegradable packaging at scale can be costly due to the higher expense of sustainable polymers compared to petroleum-based plastics. Increased demand will reduce these costs, but quality control remains essential. Ensuring food safety and consumer acceptance in alternative materials is a critical part of the transition.

EIT Food is seeking to co-fund sustainable packaging innovations through our Impact Funding Framework.

Enabling packaging innovation through policy and education

Policymakers have a vital role. Improved EU regulations will enable new packaging innovations to succeed and penetrate the market. In 2024, the EU did strike a deal to make packaging more sustainable and reduce waste (16). Yet, progress on a global level faced setbacks as UN negotiations for a legally binding agreement on plastic pollution stalled (17).

It is equally important to invest in education. Specialist courses that combine technical and personal skills training can foster the next generation for European innovators. A good example is the group of students that developed a crab shell-based packaging as part of EIT Food’s Reuse2Repack course. They went on to form the startup Chitopack.

Solving the global packaging problem will require raised ambitions and system-level approaches. Education, collaboration and policy alignment all play a role in supporting innovation. Get this right and we can enable sustainable packaging at scale that benefits both people and the planet.

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