Fibre-based packaging, refill systems, mono-material formats and packaging designed for recyclability were among the key themes discussed during the Australasian Institute of Packaging's (AIP) State of Industry Update: Interpack Discoveries 2026 webinar.
The webinar, moderated by AIP president John Bigley, brought together five Australian delegates and AIP members who attended interpack 2026 in Düsseldorf, Germany: Fonny Chang, packaging specialist at Woolworths; Lindy Hughson, managing editor of PKN Packaging News and president of the International Packaging Press Organisation (IPPO); Jean-Francois Roiron, founder and inventor at koor; Shannon Doherty-Andall, sustainability manager at the Australian Beverages Council and board member at AIP; and Nerida Kelton, executive director of AIP and vice-president Sustainability & Save Food at the World Packaging Organisation (WPO).
Several panellists noted that the European Packaging and Packaging Waste Regulation (PPWR) is acting as a major catalyst for packaging innovation, with suppliers across the exhibition showcasing recyclable mono-material structures, fibre-based alternatives and designs intended to meet future regulatory requirements.
Fibre focus gathers momentum
Chang said fibre-based innovations were among the most notable developments she encountered at the show, showcasing PulPac's fibre-based bottle and cap developments, along with a fibre meat tray developed with Zipform that integrates liquid management into the tray structure.
"I was really impressed with their constant effort to challenge the limit of fibre-based packaging," Chang said.
She said the developments demonstrated how fibre materials are being pushed beyond traditional applications, with the Zipform collaboration removing the need for a separate absorbent pad by integrating moisture management directly into the tray design.
Chang also pointed to Metsä Group's Muoto technology, which converts wet wood pulp directly into rigid three-dimensional shapes without intermediate processing steps, producing lightweight fibre trays for food packaging applications.
Hughson said advances in barrier paper technology were evident throughout the exhibition, citing the GuardDuo ice cream cone sleeve developed by Sappi and Huhtamaki.
The paper-based structure is designed to replace foil-paper laminates traditionally used for ice cream cone packaging while maintaining grease resistance and freezer performance.
"What was interesting to me was to see many advances in barrier papers driven by massive rise in fibre focus," Hughson said.
Kelton concurred that fibre-based packaging had progressed significantly since the previous interpack, highlighting AISA's PaperX Fibre Top tube developed with Blue Ocean Closures.
"To their credit, they kept going, and they kept going, and now they have a new partnership with Blue Ocean," Kelton said.
The solution combines a fibre-based tube, shoulder and closure, with both the tube and cap containing 85 per cent fibre content.
Kelton said the development demonstrated how rapidly fibre packaging technologies have progressed since the previous interpack, noting that both the tube and closure now meet the recyclability and pulpability thresholds required under emerging European regulations.
Kelton also highlighted Papack's fibre-based seafood box, developed as an alternative to expanded polystyrene. Made from a combination of wood fibre and industrial hemp, the box is designed to withstand chilled seafood applications while offering stackability and transport efficiencies.
Refill and reuse continue to evolve
Roiron, whose own innovation is the koor reusable and refillable food container, focused on refill and reuse systems, highlighting German company Vytal's deposit-free reusable container model.
"They claim they can do 200 cycles," Roiron said.
He described Vytal as one of the most successful examples of reusable packaging at scale, operating a digitally enabled deposit-free system across restaurants, hospitals, hotels and stadiums. The company now operates in 17 countries and uses digital tracking technology to manage container returns and usage.
Roiron also observed that larger brands are starting to develop their own refillable packaging systems and refill infrastructure, but noted that, in general, progress on the reuse front is slow.
Recycling compatibility a key theme
Doherty-Andall highlighted a refillable bottle made from sugarcane-derived polyethylene under the I'm Green brand.
While not biodegradable or compostable, she said the bottle can be recycled through existing polyethylene recycling streams.
"The sustainability benefit is really about reducing fossil inputs while keeping the material compatible with existing systems," she said.
Doherty-Andall noted that unlike some bio-based materials, the sugarcane-derived polyethylene is chemically identical to conventional PE, allowing it to be collected and recycled through established infrastructure without requiring new processing pathways.
She also pointed to CCL's WashOff label technology, which enables labels to separate more easily during recycling wash processes, helping reduce contamination and improve material recovery.
According to Doherty-Andall, the technology can operate at lower washing temperatures while improving recycling yields and supporting the production of higher-quality recycled content.
New approaches to packaging functionality
Hughson also highlighted Sonoco's CaponCan resealable steel container, launched at Interpack as an alternative to premium glass jars.
The vacuum-sealed steel pack incorporates a twist-open closure and can be reclosed after opening, offering potential applications in categories such as pet food and pantry products.
She also pointed to Sonoco's microwaveable steel bowl, developed as a potential alternative to plastic ready-meal trays.
Among the more novel innovations discussed was a freshness indicator label from Inno highlighted by Chang. The label uses reactive inks that respond to gases inside a package, providing a real-time visual indication of product condition.
Unlike conventional best-before dates, the indicator changes colour as product freshness declines, potentially helping reduce food waste while improving food safety communication.
Kelton also highlighted Greiner Packaging's mono-material "click-in" closure system, which combines improved recyclability with accessibility features. Designed to provide a tactile and audible confirmation when sealed, the closure was developed to improve openability, resealability and leak resistance while maintaining mono-material construction.
Other innovations featured during the webinar included tethered caps for liquid paperboard cartons, accessible packaging closures, mono-material food packaging formats and freshness-monitoring technologies.
Reflecting on the show, panellists agreed that fibre-based packaging, mono-material structures and packaging designed for recyclability have moved firmly into the mainstream. Several speakers pointed to the influence of PPWR in accelerating development activity, while noting that many of the solutions on display are likely to shape future packaging design and materials choices well beyond Europe.
If you are an AIP member, you can contact the AIP office to get access to a recording of the full webinar.
