Packaging is experiencing a epochal transformationsilent but unstoppable, which will bring concrete news in everyone’s life. We will see from food containers to merchandise wrappers up to the bottles of cosmetic and pharmaceutical products materials not only redesigned to reduce waste and ensure greater safetybut also able to interact with the content to extend its life. The plastics themselves, which will remain irreplaceable allieswill be rethought for a 100 percent recycling.
Today’s plastics and the challenges of recycling
At the moment, the packaging landscape remains dominated by those fossilsthat is, originating from oil, and omnipresent on supermarket shelves. The main ones are: the Pet (polyethylene terephthalate), typical material of water bottles and food trays; The For example (polyethylene), used mainly for transparent films, internal milk carton linings and detergent and cosmetic bottles; The pp (polypropylene), of which jars, caps and flexible refills are made; finally the Ps (polystyrene), typical of yogurt containers and other lightweight packaging.
Active packaging: when the packaging “talks” to the contents
Annalisa Apicella, researcher at the industrial engineering department of the University of Salerno, has just spoken at Instm Young Researcher’s Forum 2025held at the Federico II University of Naples, illustrating the innovations in sustainable packaging. «The new paradigm is to balance performance and sustainability» underlines a Panorama Apicella.
«To understand what we mean by performance, let’s take the case of foods: the packaging must protect from microbial contamination, oxygen, light, humidity and other environmental factors, and then extend the shelf-life, i.e. the life time of a product on the shelf. All this in full compliance with the regulations on Mocha (materials and objects intended to come into contact with food)”.
Following this philosophy, the research is slowly revolutionizing the sector. The most innovative frontier is that of active packaging: «In supermarkets we will soon see packaging that does not simply contain, but interacts with food to preserve it for longer. In some Asian countries, such as Japan, these solutions are already widespread on the market, while in Europe they are now starting to appear, albeit with more restrictive rules.”
«Of particular interest are the films consisting of biodegradable polymers or modified starchenriched with natural antioxidants and plant extracts rich in polyphenols, antimicrobials, oxygen and ethylene absorbers».
From edible coatings to single-layer materials
Not only these new solutions they extend the life of the productbut offer a sustainable alternative to conventional plastics, contributing to reduce food waste. «Among the active, biodegradable and multifunctional packaging solutions developed by our research group are plastic films polylactic acid with natural antimicrobial, protein coatings based on whey and antioxidant extracts from olive pomace and vegetation water, e biodegradable films for the controlled release of quercetin, a powerful natural antioxidant” adds Apicella.
Another interesting research perspective is represented by edible coatingsthin edible coatings made from natural biopolymers applicable directly on the food to slow down the degradation processes. An American company is producing one based on silk fibroin dissolved in waterwhich when sprayed on fruit and vegetables prolongs their shelf life.
Towards single-material and 100% recyclable packaging
«Another epochal change concerns the redesign of the multilayer packagingfrom flexible pouches to rigid trays, which are evolving towards structures monomaterialthat is, composed of a single type of plastic (for example all Pe or all Pp), or of different easily separable types.”
In many cases, as for PET or PP traysthis transition has already begun, but the goal is to extend the design for total recycling to all packaging. Today, in fact, many are still made with multilayer laminates difficult to separate and therefore to recycle efficiently.
Just think about the bags of chips or cereal bars: they look like plastic, but they are multi-material laminates composed of Pet, aluminum and Pe, difficult to separate.
Paper-based solutions and weight reduction
Another strategy aims at replacement of conventional plastics with packaging in coupled paper with thin layers of biopolymers that protect against gas and humidity. This is the case of new “paper-based” snack or coffee bagsmuch easier to dispose of.
«Demonized in public opinion, the plastic remains an irreplaceable ally. The problem arises when it is not managed at the end of life and ends up in the environment. But if well managed, it becomes an ally: it is light and can be recycled using less energy than glass and metals. PET melts at 270 degrees, glass at 1,500, metals do not go below 800″ explains Apicella.
The new European rules
The packaging revolution takes place within the framework of Packaging and Packaging Waste Regulationthe new European legislation that replaces the Directive 94/62/EC. The EU wants it progressively reduce the weight and number of packagingeliminating excessive or multiple ones and encouraging reuse.
- 5% reduction by 2030
- 15% reduction by 2040
Furthermore, by 2025 the 65% of packaging must be recyclablea share that will rise to 70% in 2030and everyone will have to report clear indications on correct disposal.
The future: less weight, more intelligence
«Perhaps someone will have noticed that some water bottles on sale have plastic so thin that it can be crushed with a hand. It is the consequence of an invisible strategy already in place: reduction of weight and thickness. Less material means **less waste and less CO₂» explains Apicella.
Not just the weight, but also the packaging design itself will minimize overall emissions, considering the entire life cyclefrom production to recycling.
The new European regulation identifies in mechanical recycling the path towards circularity: “degradable” bioplastics will have a targeted role, but will not replace conventional polymers.
Goodbye to false “eco” labels
Another important point: they will be Vague statements prohibited as “biodegradable” or “ecological” without explaining where, how and how long the degradation takes place. A material can only be said to be sustainable if degradable under precise and controlled conditions.
After all, the concept of sustainability is too complex to leave to the layman.
