How to Switch from Plastic to Paper Packaging

Once you’ve planned your transition from plastic to paper packaging, the next step is to put your plan into action. This is when you’ll work out the minute details of your plan and execute your strategy. Here’s how to implement the change from plastic to paper packaging.

1. Find a Paper Packaging Supplier

A dedicated paper packaging supplier can help you navigate your transition, so it’s best to identify who you’re going to work with at the beginning of the implementation process.

It’s critical to carefully vet suppliers:

• Do they have a knowledgeable team that’s well-versed in different types of paper, finishes, and packaging applications?
• Do they offer detailed guidance and ongoing support?

Traditional suppliers are only concerned with making a sale; they’ll tell you what you need to hear to write the check. Strategic suppliers will provide guidance every step of the way, as they believe their success hinges on your success.

A strategic supplier’s goal isn’t to sell you the highest-priced item, but to help you achieve your goals. They’ll help transition from plastic to paper packaging and identify cost efficiencies along the way because they want to be your long-term partner.

2. Choose Paper Options

Carefully consider which paper options can replace your current plastic packaging – but keep in mind that you’re not necessarily seeking an identical replacement in paper form. Rather, you want to take advantage of paper’s unique properties to place your products in better, more sustainable packaging, and that might require investment in research and development.

A knowledgeable supplier can help you evaluate the advantages and disadvantages of various papers for different applications. For example:

• SBS vs. CRB
• The best papers for products such as beer and soda that require moisture-resistant packaging
• The strongest, thickest materials and designs for heavier products

3. Employ Creative Design

One advantage to paperboard packaging is the ability to employ creative designs that pop off the shelf. For example, you can embellish your packaging with foil stamping, embossing, and debossing for a unique, eye-catching, attractive appearance. You can also enhance security with anti-counterfeit packaging. Some of these design attributes are difficult to achieve with plastic unless you use labels, which creates an additional expense and production process.

Paper helps expand your brand, so consider how to take advantage of creative design opportunities. Real-world scenarios include:

• Multi-purpose diaper boxes: Diaper boxes that kids can color after use. Think “outside the box” to identify ways packaging can be used after the packaging is no longer needed for its original purpose
• Die-cut candle boxes: We die-cut the top of candle boxes into flower shapes for striking brand appeal
• Paperboard sleeves: We replaced fully enclosed cartons with paperboard sleeves to minimize materials and cost

The best strategy is to choose a supplier who can provide design mockups that allow you to see, feel, and hold packaging – and make changes – before committing to final production.

4. Start with Quick Wins

When you convert from plastic to paper packaging, we recommend starting with relatively simple packaging. For example:

• Socks and underwear don’t require plastic bags, so you can easily switch to a paperboard header that hangs on store racks
• Earplugs often come in small plastic bags, but they can be easily replaced with paperboard pillow packs
• Any packaging that is currently utilizing plastic materials but does not require an oxygen or moisture barrier is a good candidate to transition to paper packaging

Once you’ve mastered the process, you can move on to more complex packaging.

5. Identify Manufacturing Processes

Next, identify which manufacturing processes will be required to produce your paper packaging. Evaluate your options, determine short-term costs, and calculate long-term ROI to make the best choice for your packaging needs.

If you’re not sure which manufacturing processes are required, what they cost, or how to project ROI, lean on outside resources who can help make those calculations and identify cost efficiencies that foster success.

Once your transition from plastic to paper packaging is in full swing, the final step is to measure the impact of your change and identify opportunities for continuous improvement. Learn which metrics matter in Part 4.