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Plastic Reduction

The Road to Plastic-Free Packaging

Moving away from plastic-heavy packaging requires more than choosing a different material. Brands need packaging that reduces unnecessary plastic while still protecting the product, supporting shelf presentation, controlling cost, meeting regulatory requirements and using sustainability claims that can be supported.

Paperboard packaging
Responsible sourcing
Material performance
Verified claims
Responsible sourcing and sustainability considerations for paperboard packaging

Plastic-reduction strategies should connect material sourcing, carton structure, production, distribution and recovery.

Sustainability Strategy

Plastic reduction works best when it starts with packaging performance

A paperboard alternative must still perform in real use. Moisture exposure, grease, weight, shelf display, shipment, printing, coatings, finishing and recovery pathways should be reviewed before a plastic-heavy format is replaced.

Market Context

Plastic-free packaging is a direction, but the specification has to be exact

Plastic became a common packaging material because it is light, durable and resistant to breakage. Those benefits are also why replacing it requires careful planning. Canada’s Single-use Plastics Prohibition Regulations address six categories of single-use plastic items, including checkout bags, cutlery, problematic foodservice ware, ring carriers, stir sticks and straws.1

Regulation

Rules are item-specific

Restrictions depend on the item, material, use case and market. Packaging teams should confirm which rules apply before changing specifications.

Performance

Alternatives must still protect the product

Plastic replacement should not create product damage, leakage, weak shelf presentation, poor handling or avoidable waste.

Claims

Plastic-free language must be supportable

A package may use less plastic without being fully plastic-free. Claims should match the actual materials and recovery options.

Paperboard Packaging

Paperboard can reduce plastic dependency when the carton is designed around the product

Paperboard is a thick paper-based material used in many folding carton formats. It can support retail packaging, food and beverage packaging, personal care packaging, healthcare packaging, promotional packaging and consumer goods programs.

The environmental advantage is strongest when the carton is designed efficiently, sourced responsibly, manufactured with controlled waste, shipped efficiently and accepted in the intended recovery stream. Paperboard selection should be based on structure, product weight, print quality, barrier requirements, display needs and cost.

Netpak supports custom folding carton programs with structural design, paperboard selection, offset printing, finishing, warehousing and logistics. This makes it possible to evaluate paperboard alternatives as part of the full package, not as a material decision alone.4

Paperboard planning should confirm

  • 1Product weight, shape, fragility and shelf format.
  • 2Paperboard grade, thickness and structural requirements.
  • 3Print quality, colour, finishing and brand presentation.
  • 4Moisture, grease, window, coating or barrier needs.
  • 5Recycling, disposal and claim-substantiation requirements.
Paperboard material selection for plastic-reduction folding carton packaging

Paperboard selection should connect plastic-reduction goals with structure, print quality, protection and end-of-life expectations.

Material Selection

The board grade has to fit the product and channel

SBS, FBB, CRB, SUS, URB and other paperboard choices can support different combinations of strength, print quality, appearance, recycled content, sustainability goals and converting performance.

Bio-Based Materials

Bio-based materials can help, but they still need performance and end-of-life review

Sugarcane-based board, starch-based materials and other plant-derived packaging options are often discussed as alternatives to conventional plastic. They may support specific sustainability goals, but they are not automatic solutions.

Source

Confirm what the material is made from

Bio-based content should be documented clearly. Plant-derived does not automatically mean recyclable, compostable or suitable for every market.

Use

Test against the product

Alternative materials still need to handle folding, filling, moisture, grease, sealing, temperature, transportation and consumer use.

Recovery

Check the local waste stream

A material may be compostable or recyclable only under specific systems, which makes local acceptance and customer instructions important.

Cost and Practicality

Plastic reduction has to work commercially

Packaging changes can affect material cost, tooling, printing, finishing, storage, transportation, pack-out, damage rates and speed to market. A lower-plastic package that creates production problems or product waste may not deliver the intended sustainability result.

The Government of Canada’s guidance for alternatives to regulated single-use plastics emphasizes choosing alternatives that prevent pollution and reduce waste, while aligning decisions with industry best practices.2 That means packaging teams should evaluate the full operational impact, not only the material substitution.

Early structural and prepress review can help identify whether a paperboard alternative needs a different dieline, stronger board, revised artwork, coating, insert, closure, window strategy or production test.

Commercial review should include

  • 1Material availability and procurement constraints.
  • 2Tooling, dieline, print and finishing implications.
  • 3Pack-out, shipping, warehousing and logistics changes.
  • 4Damage prevention and product-waste risk.
  • 5Consumer instructions and sustainability-claim controls.
Dieline planning for paperboard packaging that reduces plastic components

Structural planning helps ensure that a lower-plastic carton remains practical to print, cut, fold, glue, pack and ship.

Structural Design

Many plastic-reduction projects succeed or fail at the dieline stage

A carton can reduce plastic use while still needing strong panel hierarchy, closure security, barcode placement, shelf visibility, coating review and distribution performance.

Responsible Sourcing

Certifications and quality systems help support responsible packaging decisions

Sustainability claims become more credible when they are connected to documented sourcing, controlled production processes, traceability and clear customer requirements.

Sourcing

Confirm fibre and board requirements

Responsible sourcing programs can support packaging goals when they are specified correctly and documented through the supply chain.

Quality

Control production consistency

Quality systems help keep specifications, printing, finishing and production controls aligned across orders and product lines.

Claims

Avoid vague sustainability language

Environmental claims should be specific to the package, material, market and recovery stream rather than relying on broad eco-friendly language.

Quality certification considerations for responsible folding carton packaging

Quality systems and certification context help support consistent production and more disciplined packaging specifications.

Quality Context

A lower-plastic package still needs controlled production

Netpak’s quality and certification context helps brands evaluate production control, traceability, customer requirements and packaging consistency across folding carton programs.5

Build a plastic-reduction packaging plan around the product

Send Netpak your current packaging format, plastic-reduction goals, product details, carton dimensions, paperboard preference, barrier or coating needs, artwork status, quantities and launch timeline. Netpak can help review structure, material, prepress, offset printing, finishing, warehousing and logistics before production.

Request a packaging review Email sales@netpak.com
Related Resources

Continue planning lower-plastic paperboard packaging

These Netpak resources can help connect plastic-reduction goals to folding carton structure, paperboard selection, prepress, finishing and quality systems.

Paperboard material selection for custom folding carton packaging
Products

Custom folding cartons

Plan structures, paperboard, printing, finishing, warehousing and logistics.

Open product page
Structural design and prepress for lower-plastic packaging projects
Prepress

Structure and prepress

Align dielines, prototypes, artwork, files and production readiness.

Open service page
Finishing and coating review for lower-plastic paperboard packaging
Finishing

Enhanced finishing

Review coatings, lamination, varnish, texture and surface performance.

Open service page
Quality systems and certifications for responsible paperboard packaging
Quality

Quality and certifications

Review quality systems, traceability, certification context and production control.

Open service page
References

Sources

  1. Government of Canada, Single-use Plastics Prohibition Regulations: Overview. https://www.canada.ca/en/environment-climate-change/services/managing-reducing-waste/reduce-plastic-waste/single-use-plastic-overview.html
  2. Government of Canada, Single-use Plastics Prohibition Regulations: Guidance for Selecting Alternatives. https://www.canada.ca/en/environment-climate-change/services/managing-reducing-waste/reduce-plastic-waste/single-use-plastic-guidance.html
  3. Paper and Paperboard Packaging Environmental Council, About PPEC. https://ppec-paper.com/about/
  4. Netpak, Custom Folding Cartons. https://www.netpak.com/en/products/folding-cartons/
  5. Netpak, Packaging Quality & Certifications. https://www.netpak.com/en/packaging-services/quality-certifications/
  6. Netpak, Structural Design & Prepress for Folding Cartons. https://www.netpak.com/en/packaging-services/structure-prepress/
  7. Netpak, Folding Carton Finishing Services. https://www.netpak.com/en/packaging-services/enhanced-finishing/