Unilever has increased its investment in packaging research and development, focusing on sustainable materials to reduce reliance on virgin plastic. The company’s Global Packaging R&D Centre is at the forefront of efforts to develop recyclable and compostable materials through its ‘Future Flexibles’ programme.
According to Pablo Costa, global head of packaging at Unilever, the company aims to strengthen its in-house capabilities while working with partners to bring sustainable solutions to market. "Our plastic progress is industry-leading, but we cannot be complacent," Costa said. "We’re optimising what we can do in-house, while collaborating with others to scale solutions."
Unilever’s strategy includes integrating more post-consumer recycled (PCR) plastic to replace virgin materials. The company acknowledges the challenges of achieving this, as recycled plastic must meet rigorous quality standards to perform like virgin plastic, including maintaining appearance, colour, and freshness.
This year, the Packaging R&D team developed a digital tool to predict packaging colour using 160 different grades of recycled plastic, cutting development time by 25 per cent. The company also uses its Advanced Manufacturing Centre, a pilot-scale plant, to test materials and designs virtually, reducing the need for physical prototypes and factory trials.
As part of Unilever’s commitment to make all flexible plastic packaging reusable, recyclable, or compostable by 2035, the Future Flexibles programme is focused on alternatives for items such as sachets and pouches. While paper is currently the only widely recyclable and compostable material available, Unilever’s research highlights its limitations, such as low barrier properties and production challenges.
"Packaging liquid products like laundry detergent and shampoo in paper is a technically complex task," Costa said. "We are developing alternatives that provide barrier protection and seal the product without compromising recyclability or biodegradability."
The company has assessed over 3,000 technologies, including those from industries such as pharmaceuticals and electronics, and is now working with partners to adapt the most promising options for packaging applications.
Unilever emphasised that voluntary business action alone will not resolve plastic pollution and called for coordinated policy changes to support scalable solutions.
Costa added, "Switching to recyclable and compostable paper flexibles will require major industry transformation. There are no quick fixes, but we are preparing our supply chain and consumers for the transition."
