The growth of the UK packaging sector is being driven by several key factors, including increased manufacturing activity, the burgeoning e-commerce market, rising demand for sustainable and recyclable packaging, and the growing importance of packaging as a marketing tool.
The sector is also benefiting from innovations in digital printing and automation.
Growing consumer awareness of environmental issues and government initiatives like the Plastic Packaging Tax (PPT) are driving the demand for sustainable and recyclable packaging options.
Andrew Grimbaldeston, Managing Director, Colpac, comments: “Our customers, and consumers, are certainly prioritising recyclable packaging, particularly as we are on the brink of major packaging industry reform. Retailers are becoming increasingly focused on this in support of lower Extended Producer Responsibility (EPR) fees, Simpler Recycling, and lightweighting. Many of our customers are also now working toward net-zero, so are looking for their packaging to be as renewable and recyclable as possible.
“This trend is bringing much innovation across the industry, in the form of new materials, coatings, and packaging formats. We work closely with our well-established supplier network to test innovations across these areas, partnering with industry leaders to bring these innovations to the food packaging market.”
Longer shelf-life packaging is an area of specialisation for Colpac, with both heat sealable and Modified Atmosphere Packaging available to extend food shelf-life.
By the nature of these products there has always been a trade-off between increasing shelf-life to support the reduction of food waste, and packaging recyclability.
This trade-off is becoming increasingly apparent as this type of packaging is classified as fibre-based composite due to the required coatings to support shelf-life extension.
Retailers and food manufacturers therefore must decide whether they prioritise pack recyclability, or food waste reduction, a decision which is becoming increasingly complex.
Colpac is well positioned to assist and advise customers on these decisions and discuss the options available.
“Packaging reform is pushing the industry towards a more effective circular economy. Packaging Extended Producer Responsibility (pEPR) is a significant opportunity for us to work towards circularity. This is supported by other regulations such as PPWR, EUDR, and Simpler Recycling initiatives,” adds Grimbaldeston.
“We are working closely with our customers, which includes operators of all sizes, and wider industry, to interpret legislation and support them with product information and the supply chain collaboration necessary for pEPR and other regulations. As a company, we are committed to supporting our customers with the intricacies of policy such as this, and our leadership in encouraging industry collaboration is central to supporting operators with the impacts of legislative change.”
Colpac’s Stagione® range is one of its key product lines which has continued to evolve since its launch in 2021. The latest addition to this range is the Stagione® Light line, which showcases the iconic shape and roll top design of Colpac’s original range, whilst offering customers lighter products that are manufactured from one piece of paperboard. This range is suited to retailers and food manufacturers as the packs de-nest very easily in a packing environment and offer all over printing and much simpler labelling.
Colpac works with major retailers and food manufacturers and packers alike to supply a comprehensive stock range and develop unique packaging solutions. When partnering with customers, Colpac works collaboratively to understand their challenges and opportunities. This helps the company to develop considered designs and work with the latest, innovative material options, and to put forward the best possible solution for each customer. Colpac then project manages the launch, on-going supply, and horizon scan for opportunities to keep the product at the forefront of its category.
“Safety is paramount to the food industry and as a packaging manufacturer it is core to our customers’ requirements. We recently announced our achievement of a BRCGS AA+ audit grade, for the second year running. We embraced our second annual unannounced audit, passing with no non-conformances and being awarded the highest grade for BRCGS audits. We voluntarily elected for the unannounced audit as a demonstration of our commitment to producing packaging that continuously meets audit ready standards,” says Grimbaldeston.
“Sustainability is embedded in everything that we do at Colpac, across product design and development and operational sustainability, as demonstrated by our leading net-zero programme. We have just moved into the fourth year of our programme, having achieved a remarkable 22% carbon emissions reduction in year three. We reduced our emissions across several key areas, thanks to our company-wide buy-in and collaboration. Progressing towards our net-zero targets reduces our impact on the environment and supports our customers in achieving their sustainability goals when they partner with us.”
Gavin Ashe, Managing Director at Kite Packaging comments: “Consumers and businesses are both increasingly prioritising sustainable and recyclable packaging. This is being driven by growing environmental awareness and a stronger commitment from businesses to reduce their impact.
A recent study shows that 70% of shoppers consider a brand’s sustainability efforts when making purchasing decisions, while 81% believe companies have a responsibility to help protect and improve the environment. Consumers are not only expecting eco-friendly packaging – many are actively choosing brands based on their sustainability credentials.
Companies are now seeking out new materials and technologies that align with circular economy principles. In response, the packaging industry has seen an upsurge in the development of recyclable, compostable, and biodegradable materials. There have also been advancements in manufacturing processes that reduce waste and carbon emissions. Materials made from renewable sources like sugarcane, cornstarch, and agricultural by-products are becoming more mainstream, while closed-loop recycling systems and minimalist packaging designs are also gaining traction.
“Sustainability is no longer a “nice to have” – it’s a standard expectation that’s changing the way products are packaged and delivered,” adds Gavin.
Regulations are steering the packaging industry toward more sustainable practices. Legislation such as the Plastic Packaging Tax (PPT) and Extended Producer Responsibility (EPR) are driving significant change across the sector.
The Plastic Packaging Tax, introduced on April 1st, 2022, places a levy on plastic packaging that contains less than 30% recycled content. Businesses now have a strong financial incentive to increase their use of recycled plastics, reduce their dependence on virgin materials, and adopt better waste management practices.
Meanwhile, EPR legislation ensures that producers are responsible for covering the full cost of managing the waste their packaging generates, from collection and sorting to recycling. This “producer pays” principle encourages companies to design packaging with recyclability in mind, as those using harder-to-recycle materials will face higher costs.
Together, these regulations reinforce the importance of circular economy principles within the packaging industry.
Sustainability continues to be the dominating trend.
There is a strong and growing shift towards recycled plastics, bio-based polymers and fibre-based alternatives as businesses reduce their environmental footprint and align with consumer demand and regulatory requirements.
There is a rising interest in biodegradable packaging made from plant-based materials, particularly in sectors such as eCommerce and food. This trend is being accelerated by legislation targeting single-use plastics, like the single-use plastic ban which came into effect 1st October 2023.
There’s also a noticeable move towards minimalist packaging design – solutions that use fewer resources without compromising on protection or performance. These designs support carbon reduction goals while also improving cost-efficiency and supply chain effectiveness.
Kite Packaging recently introduced anti-slip pallet sheets, aimed at stabilising palletised loads without using plastic pallet wrap.
The sheets are made from sustainably sourced, recycled paper and are fully recyclable. They feature an anti-slip coating and have been tested to TAPPI 815 standards for friction control, ensuring stability at angles up to 50?regardless of speed and terrain.
Kite Packaging also expanded its popular Kite Enviro Mailers range. These strong, durable mailers are manufactured in the UK from paper with 70% recycled content, featuring a honeycomb inner layer for added protection. They are fully recyclable, providing an environmentally responsible postal option for ecommerce businesses that can replace plastic mailers.
Andrzej Kukula, Technical and New Product Development Manager, KM Packaging, comments: “The end consumer has a renewed focus on recycling and waste reduction across the board, driven from a need to protect the environment and reduce impact on the planet. This is a simple and direct message from the shopper that requires a large number of different innovative solutions for the vast variety of packaging applications in the average shopping basket. For KM and our customers, the producers of the food in those baskets, there’s a real drive to reduce packaging across the board make sure what is used is the best sustainable option for that application. Our role at KM Packaging is to provide the innovation in flexible packaging that makes this possible.
“Shelf life is a huge concern, and it is key to the producer that their product has the longest time available to be purchased. Extending this shelf-life range is one of the ways we can make a marked impact on the issue of food waste. There’s a tension in the market between recyclability and food waste, as the simple truth is that plastic films and plastic trays will improve shelf life and contribute to reduced food waste at the store level. We’ve innovated with high barrier paper products, mono polyolefins with better recyclability, and 30% PCR content films.”
The food industry is reckoning with the changes coming in with the Extended Producer Responsibility fees later this year – until this kind of economic force comes into play, the incentive to change packaging towards more sustainable options was primarily from consumer pressure.
The flexible packaging business is focusing on moving customers away from mixed materials to recyclable mono materials where the application is appropriate so that they can benefit from lower fees. Where not appropriate KM Packaging is working on downgauging flexibles to reduce plastic content. This also means customers benefit from more recyclable plastics – as far as they’re supported locally.
“We’re a global business, and while food waste and recycling is a global issue, each region is developing their own ways to combat it via legislation,” adds Kukula. “With that, the trend we’re seeing is a plurality of sustainability goals from companies across the sector – whether that’s focusing on CO2, food waste, plastic reduction or something else. We take the time to fully understand our customer’s goals and developing the right materials to match, as we’ve been doing for 40 years. Ultimately packaging and sustainability is key to a brand’s success and this multifaceted approach to sustainability will continue as individual brands build up confidence in not only in the product, but in the packaging.”
KM Packaging has been working on various products, such as the recently launched K-Nature Paper HBe a high barrier paper-based material. It’s seen a lot of interest as it fits the bill for sustainability and the environment – offering kerbside recycling in major markets. Additionally, the company has worked on mixed/mono PO limited film solutions for PET and PP trays which peel – offering further sustainability options for specific customer applications.
KM has a large focus on new product development, with many films and formulations developed to directly answer demanding applications from customers. The company has developed a new paper-based barrier product that is widely kerbside recyclable called K-Nature Paper HBe. KM has also developed some high performing mixed and mono polyolefin films, sustainability focused 30% PCR content grade films, and high barrier options in mono PET.
“We need to look beyond the popular headlines that ‘plastic is bad’ and find the solutions which give us real benefits,” says Kukula. “Plastic packaging has a role to play in reducing food waste – but we can reduce material, increase recyclability and improve product shelf life, and reduce our CO2 footprint with the right approach.”
Simon Dix, Managing Director of Vetroplas comments: “We are seeing ever increasing demand for green packaging solutions, leading to development of new parts in recyclable materials. Due to ongoing legislation this development will need to continue.
“We also see customers driving this demand as we all need to consider how best to comply with government legislation.”
Packaging trends include a move from some materials to others e.g. from glass and plastic to aluminium, plus the increased use of post-consumer recycled (PCR) content.
Vetroplas provides primary packaging in glass, plastic and aluminium for cosmetics, personal care and drinks markets.
The Plastic Packaging Tax has had a significant impact on packaging manufacturers. Vetroplas’ European manufacturing partners, like many, have been working for years to broaden their ranges offering an element of sustainability, be it recycled content, plastic derived from sugar cane extract, mono materials etc.
These elements are at the forefront of any new range designs.
Vetroplas is now able to offer many cosmetic glass bottles with a high percentage of recycled content whilst maintaining a premium, clear finish. It is able to produce many of its most popular skincare glass bottles with 90% recycled glass content and a clear finish.
Additionally, Vetroplas has a wide range of aluminium bottles with standard screw neck finishes and recycled content. Aluminium is already infinitely recyclable, but Vetroplas can now make bottles with up to 100% recycled aluminium without affecting performance.
Of all the options available the strongest demand is now consistently for recycled content plastic, glass and aluminium.
Vetroplas makes cosmetic glass and aluminium bottles for toiletries, household and drinks. It is known for being able to supply a finished pack with full decoration and, often, with a closure.
The company’s customers include the major contract manufacturers in the UK plus brand owners.
It supplies packaging for cosmetics, skin care, personal care, household cleaning products and aluminium bottles for drinks.
Together with its factory partners Vetroplas continues to strive for packaging which is less impactful on the environment including weight reduction, recycled materials and refillable solutions.
Vetroplas is trying to make information about its ranges more accessible. For example, its most sustainable ranges of glass and plastic have now been collated into one catalogue and website.
The company also now has all plastic droppers, including the dip tube, enabling brands to present fully recyclable dispensing packs.
It is now offering a high quality spray frosting finish on its glass bottles and jars as a more sustainable alternative to acid etching.
In order to mitigate the compromises involved with selecting greener packaging, Vetroplas is also offering a higher grade of recycled plastic called Prime. This is the result of a higher selection process of recycled raw material. The benefits include fewer inclusions, a lower intensity smell and a more vibrant finish when coloured.
Ingrid Lidbäck, Marketing Director at Graphic Packaging, comments: “Consumer data from the latest Pro Carton survey shows that consumers across Europe are continuing to prioritise purchases they perceive to be sustainable. It revealed that 64 percent of consumers continue to look for sustainable products, provided these products are not more expensive than the alternatives, and over half of consumers consider the environmental impact of their purchasing decisions when at the point of sale.”
Legislation is also an important driver – pEPR is currently being rolled out across the UK, which incentivises the design of packaging for recyclability and the removal of unnecessary packaging components, through modulated fees, as does the EU’s imminent Packaging and Packaging Waste Regulation (PPWR).
PPWR will set new Design for Recycling (DfR) criteria and enforceable targets for waste reduction by the end of the decade, and Graphic Packaging is already supporting many of its customers in developing compliant packaging solutions.
Graphic Packaging has worked with retailers like Morrisons and Sainsbury’s to transition private label protein lines from plastic packaging into paperboard and has enabled many UK retailers and growers to move fresh produce products from plastic punnets into paperboard with solutions like the ProducePack™ Punnet tray.
“It’s important that the new generation of circular packaging solutions offer equivalent levels of convenience to consumers,” adds Lidbäck. “Our mission is to keep getting ‘better, every day’ and bring consumers with us on the journey. We can’t do that unless we ensure new packaging delivers everything that they expect.”
The real driver of innovation is the need to balance convenience and shelf life with regulatory compliance, cost and operational efficiency. Ticking all these boxes requires innovation.
Intelligent structural design can make a big difference to convenience, shelf life, and operational efficiency, Graphic Packaging’s PaperSeal™ Shape paperboard tray being one example. The unique one-piece double flange delivers an excellent hermetic seal for modified atmosphere (MAP) and vacuum skin (VSP) applications to maintain shelf-life versus plastic trays. It’s a very rigid tray, which performs really well through the supply chain. It’s also been designed to run on existing tray filling and sealing machines, so packers can easily switch between plastic and paperboard trays and there’s no capital investment required.
“There’s often a misconception that if you move to paperboard solutions, shelf life might be compromised, particularly for more sensitive applications, but with intelligent barriers and design, this isn’t the case,” says Lidbäck. “This was proven in an independent shelf-life study, carried out by Washington State University, that tested the shelf life of cherry tomatoes when packed in paperboard ProducePack™ Punnet trays compared to plastic trays. Results showed that cherry tomatoes exhibited significantly less mould growth in the paperboard punnet tray in both refrigerated and ambient conditions, and mould growth occurred much sooner in plastic punnets.”
PPWR and EPR, along with many other recent sustainability regulations, like the plastic packaging tax, contain explicit incentives to minimise packaging weight and to reduce the use of plastic in favour of a move to more easily recyclable alternatives.
The disparity between access to plastic recycling and the recovery of plastic material is a global problem. In Europe, paperboard recovery rates are roughly double those of plastic. Just because a consumer might drop a plastic tray or wrapper into their recycling bin, doesn’t mean it will be successfully recycled due to the higher cost of recycling plastic versus using virgin material – and consumers are increasingly aware of this.
Ben Elkington, Innovation Director Food Packaging at Klöckner Pentaplast, comments: “We’re seeing unprecedented demand for sustainable packaging solutions, which drives our continuous portfolio transformation through design innovation. Our approach ensures products are designed for recycling, maximise recycled content use, and optimise resource efficiency – making them part of the circular economy solution, not the problem.
“As a leader in the packaging industry, part of our role is to help customers navigate complex legislation like the Packaging and Packaging Waste Regulation (PPWR). A key part of that is arming them with knowledge on how these regulations are changing the packaging landscape, and where kp’s innovations address these challenges.”
At FachPack 2024 and CFIA 2025, Klöckner Pentaplast offered expert sessions on PPWR implementation, tying into its latest food packaging solutions. Its commitment is to make sustainability accessible through clear information and practical innovations.
“Stringent waste regulations are compelling packaging teams like ours to reach unprecedented levels of innovation and creativity,” adds Elkington. “Instead of being roadblocks, these challenges have become real catalysts for change at kp, energising our team and driving us to rethink what’s possible in sustainable packaging design.”
The company’s response includes solutions like kp MonoSeal®, a mono PET rigid film that delivers exceptional sealing performance while containing up to 80% post-consumer recycled content. Similarly, its kp Elite® trays incorporate up to 100% recycled PET without compromising performance, recently earning the prestigious TCEP endorsement that sets new European recyclability benchmarks.
“Perhaps most exciting is how these regulations have sparked greater collaboration across our teams, resulting in integrated systems like our recyclable barrier lidding film kp FlexiLid® EH 145 R, which pairs perfectly with our trays to create complete PPWR-compliant solutions,” says Elkington.
“What we’re seeing across the packaging market goes far beyond compliance – it’s a fundamental reimagining of packaging’s role in a more circular economy, with innovation thriving under regulatory pressure.”
Sustainability remains the primary driver, but there are interesting shifts emerging in how it’s being implemented. Retailers and brand owners are moving beyond basic recyclability to demand complete circular solutions with verified traceability. The concept of “design for recycling” has switched from theoretical to practical application, with customers now seeking evidence of closed-loop systems, like the kp Tray2Tray® initiative.
There’s also growing emphasis on resource efficiency – packaging that uses less material overall, while maintaining or improving performance. Newer barrier films on the market, for instance, can reduce plastic usage by up to 75% compared to traditional options, without compromising protection.
Regulatory preparation has also become a defining trend, with forward-thinking businesses actively seeking PPWR-ready solutions now, rather than waiting for looming implementation deadlines.
Klöckner Pentaplast’s best-known products bring together market-leading kp Elite® mono rPET MAP trays with its award-winning kp Zapora® padless technology. This powerful combination has achieved both RecyClass Class A certification and the prestigious TCEP endorsement for recyclability. Available with up to 100% post-consumer recycled content, these trays systematically incorporate the kp Tray2Tray® material, creating a genuine closed loop for food packaging.
The company is also recognised for kp MonoSeal®, our mono PET rigid film that delivers reliable hermetic seals in challenging applications like sliced cheese and processed meats, while containing up to 80% recycled content and maintaining complete recyclability.
It also offers kp FlexiLid® EH 145 R barrier lidding film, certified recyclable by Interseroh and cyclos-HTP.
Containing over 90% PE and designed following Ceflex guidelines, it exceeds packaging specifications while offering superior product protection and presentation.
Stuart Graham, Head of Convenience and Impulse at KP Snacks, comments: “Protecting the environment is one of the core pillars of our People and Planet programme. As a responsible snacks manufacturer, we are committed to taking a proactive approach to reduce our carbon emissions and safeguard the planet.”
In line with its commitment to using as little plastic packaging as possible, KP Snacks recently launched an additional investment in flow wrap equipment. The flow wrapping process reduces plastic packaging across three of its most popular Everyday Value (EDV) brands: Discos, Roysters, and Frisps. Equivalent to 100 tonnes of packaging, the flow wrapping process will see a 35% reduction in plastic packaging for 6-packs across the three brands.
Meanwhile, with more products able to be transported at once, KP Snacks’ lorry journeys will decrease by 620 annually, reducing greenhouse gas emissions from transport. As well as appealing to increasingly environmentally conscious consumers, the new flow-wrapped packs will create more space on shelves, enabling retailers to display extra stock and drive sales.
In addition to this, KP Snacks recently introduced 25% recycled content packaging across its popular Tyrrells sharing range. Incorporating recycled soft plastics, this move reduces the company’s reliance on virgin plastics for packaging and supports a circular economy in line with its commitment to the UK Plastics Pact.
Daniel Coates, Business Development Director, LVF Packaging, comments: “There seems to be a lot of innovation regarding materials and processes, but none seem to be making it to the shelves in significant numbers due to several factors. There has been a lot done with various biodegradable and compostable plastics, but they seem to be prohibitively expensive and run the risk of confusing consumers as to what they should be doing with them at their end of use. Similarly, there has been a lot of work done in the moulded pulp fibre world, but again they are an expensive option and not suited to all cases where regular plastics are used.”
LVF Packaging has been supplying rPET mono trays for a number of years, this being the most recyclable of plastics. Many customers are now moving away from the laminated rPET/PE trays due to cost and regulations.
The company’s biggest customers are Morrisons, Lindt and stockist supplier DBM Packaging, for them it makes a range of trays for protein and confectionery.
LVF Packaging has recently invested heavily in solar and battery storage to be more energy efficient, and it also has a closed loop system with suppliers meaning all process waste is recycled.
Stephen Gryczka, Director Strategy and Corporate Development at Markem Imaje, comments: “In 2024, retailers navigated relentless inflation, ever-changing consumer trend cycles, and persistent supply chain challenges. These hurdles may evolve but they won’t disappear in 2025. Retailers must continue to effectively manage inventory amid rapidly changing consumer preferences as well as uncertain geopolitical conditions that can exacerbate pricing pressures and impact retailers’ profitability and operational efficiency. Additionally, they must win over shoppers still grappling with rising costs of living. It’s a tall order, but sometimes the most transformative tools are closer than we think. The 2D barcode (or QR code) on packaging can unlock new, streamlined pathways for efficient inventory management and consumer engagement, empowering retailers to meet the demands of a complex market and succeed in a changing world.”
Two-dimensional (2D) barcodes are graphical images that store large amounts of data for access by consumers and workers.
While today’s standard UPC (1D) barcodes can only convey a limited amount of data on packaging, like item identification and pricing, 2D barcodes stand to carry a much wider range of information.
Though the technology has existed for almost more than 30 years, 2D barcodes rose in popularity during the COVID-19 pandemic as the default access point for restaurant menus and routine forms to facilitate a no-touch or low-touch consumer experience.
As the world becomes more technologically centred, consumers demand access to more product information, and retailers and brands must evolve.
For decades, the standard barcode has served retailers’ needs to track products but cannot meet the increasingly complex consumer demands and business needs.
2D barcodes enable a single point for retailers to access product information such as inventory levels, sell-by dates, country of origin, and recall notices. This breadth and depth of 2D barcodes offers critical opportunities for retailers to streamline inventory management, reducing manual labour costs to reduce human errors, explore dynamic pricing, and increase engagement with shoppers for conversion.
However, adoption will take time and guidance. GS1 is the global organisation for data exchange standards and the organisation behind GS1 Digital Link, the standardised model for encoding information within a 2D barcode, which can be scanned at checkout and connected to online information. Recently, GS1 activated the Sunrise 2027 to encourage the widespread adoption of specific GS1 standards for Digital Link to better share data. The initiative encourages widespread use of Digital Link on product packaging by 2027, with retailers able to scan both the 2D and barcodes at Point of Sale (POS).
This seismic shift in retail operations may sound daunting, but it presents an exciting opportunity for retailers to collaborate across their supply chain and utilise data to its full potential. Throughout this GS1 Digital Link transition, retailers should keep three priorities top of mind for success – streamlining inventory management, supporting retail brands, and engaging consumers.
Comments are closed.