Replacing plastic is no longer the end goal for fibre packaging. At foodpro's Innovation Stage, panellists argued the next generation of fibre solutions will be defined by systems thinking – balancing product protection, automation, recyclability and commercial reality.
Fibre packaging innovation is evolving beyond the search for alternatives to plastic, with Australia's leading developers now focused on designing solutions that work across the entire packaging system.
That message emerged throughout an Australasian Institute of Packaging (AIP) panel discussion at foodpro, where moderator Keith Chessell guided a conversation exploring the opportunities and challenges shaping the future of fibre-based packaging.
Bringing together Mark Rohrlach, regional manager – Asia & Australasia at Detpak; Ola Wicik, packaging engineer at Opal; and David Kilpatrick, managing director of Zipform Packaging, the discussion highlighted how advances in fibre technology are increasingly being driven by collaboration across the supply chain rather than by materials innovation alone.
Throughout the session, Chessell returned to the importance of designing packaging as part of a broader system, challenging panellists to explain not only how their products perform, but how they integrate with existing production lines, logistics networks, recycling systems and consumer expectations.
That systems approach was evident across each of the innovations discussed.
For Detpak, fibre innovation in fresh produce has centred on helping growers reduce their reliance on plastic while maintaining the speed and efficiency of automated packing lines. Rohrlach said new solutions must meet sustainability expectations without compromising food protection or operational performance.
“The packaging development team has to deliver options that also survive the supply chain, survive all the existing filling lines, and also present the product that's going into it exceptionally well,” he said.
Detpak's fibre tomato punnet, developed in collaboration with Perfection Fresh, illustrates that philosophy. Rather than simply replacing an existing plastic pack, the project required modifications to automated equipment, multiple production trials and close collaboration between engineering teams before reaching supermarket shelves.
“When you've got somebody that wants to make that change, it's a far easier journey because they're willing to accept those challenges as they come along. All part of the new product development journey,” Rohrlach said.
Opal's Arctic Shield insulated fibre carton reflects a similarly holistic approach. Originally developed as an alternative to expanded polystyrene for seafood and other cold chain applications, the latest generation has been redesigned to meet more demanding transport requirements, including longer cold chain performance and leak-proof construction.
Wicik said customer expectations had shifted beyond simple material substitution.
“We had to really reconsider the entire packaging system and redesign what we already had, but redesign it to be fit for purpose for those new restrictions,” she said.
Looking ahead, she suggested corrugated packaging's future will depend less on breakthrough materials than on smarter engineering, lightweighting and optimising packaging throughout the supply chain.
“We don't want to make corrugated work harder. We want it to work a lot smarter,” Wicik said.
The broader theme of collaboration also featured strongly throughout the discussion.
Wicik argued that packaging is too often considered at the end of product development, despite influencing manufacturing, automation, transport, retail handling and the consumer experience.
“The greatest success from our customers will be those who really understand that packaging is a part of their entire system, not just an afterthought,” she said.
Chessell reinforced the point, drawing on decades of experience in packaging development to encourage brand owners to involve packaging suppliers much earlier in the design process. Better outcomes, he said, come when packaging, equipment and product development teams work together from the outset.
Innovation is also being driven by advances in fibre converting technologies. Kilpatrick outlined Zipform's work in linear forming and its recent partnership with PulPac to develop dry moulded fibre applications, including high-barrier meat trays without a separate plastic layer – technology PKN has previously reported on.
Comparing dry moulded fibre to conventional wet moulding, Kilpatrick said, “It offers a lot of benefits, but first and foremost, it's much less energy intensive and much less water-use intensive, and much faster... and it offers greater design flexibility.”
Recyclability, recycled content and evolving PFAS requirements also featured prominently during the session, with panellists emphasising that sustainability outcomes depend on balancing fibre recovery, food safety, barrier performance and practical manufacturing considerations.
While the innovations showcased differed in application – from fresh produce and seafood to meat packaging and paper bottles – they shared a common direction.
The discussion made clear that fibre innovation is no longer about replacing one material with another. Future success will depend on designing packaging as part of a complete system that balances product performance, manufacturing efficiency, recyclability and commercial viability.
