Karen McIntyre, Editor11.11.24
Driven by legislative restrictions, such as the European Union’s Packaging and Packaging Waste Regulation (PPRW), as well as consumer demand for sustainable options, manufacturers of consumer products like hygiene items and wipes are increasingly adopting more sustainable packaging and waste management practices. However, sourcing and paying for alternative materials is not always easy, nor is paying a higher premium for these solutions.
“There is no doubt that sourcing more sustainable packaging materials can be challenging. The supply chain for these materials is still evolving. In some regions, supplies are limited and prices are therefore high compared to traditional materials,” says Guido Conio, chief commercial officer, IMA Teknoweb. “But demand is growing, so many new suppliers are entering the market with new solutions: demand is a great driver of innovation. At IMA, we work closely with our suppliers to ensure our customers have access to high-quality, sustainable materials and support them in adapting their processes to use these alternatives without compromising efficiency or product quality.”
As a provider of complete manufacturing lines, IMA has heavily invested in R&D to address challenges related to the machinability of sustainable products. For example, plastic-free wipe materials often have a specific fiber fragility, which can lead to heat sensitivity and breakages during production. To overcome these issues, IMA has equipped its converters with advanced features, including unwinders with tension control, zero-speed splicing, low-friction turning bars, and a multi-step wetting system.
Similarly, machinery specialist GDM has seen some players are now starting to evaluate more sustainable packaging options.
“Regarding consumer preferences, research shows that sustainable packaging is gaining traction among environmentally-conscious buyers, although they still represent a niche within the global disposable products market,” says a GDM spokesperson. “Along with a lack of awareness, the typically higher price of greener products is deterring mass purchases.”
GDM has been testing new packaging options made from 100% non-oil-based green polymers, low-density polyethylene (LDPE), and recycled plastic materials, providing greener alternatives to conventional plastic. For example, the non-oil-based green polymers we use are derived solely from renewable resources like starch. Another example is low-density polyethylene bags, which have a reduced thickness compared to standard ones, allowing for a decrease in virgin polyethylene usage while also contributing to material cost savings.
“Regarding recycled materials, we have been exploring the use of post-consumer resin (PCR)—plastic that has already been recycled and is ready for reuse,” the spokesperson says. “Our bags, made with up to 20% PCR, support a low-carbon circular economy without compromising on quality.
“Additionally, we have successfully introduced mono-material solutions, such as paper bags, which enable easier waste management and faster recycling. Finally, through synergies with Coesia companies, we are now evaluating alternative solutions for secondary packaging as well.
“Alternative packaging materials remain a niche market with relatively low volumes compared to traditional materials, resulting in a limited supply from raw material providers. However, recognizing the growing demand for sustainable options, suppliers have developed innovative solutions to meet industry needs. As interest in eco-friendly packaging rises and government initiatives increasingly drive sustainability, demand for these materials is expected to grow.”
“We wish to make it easy and convenient for parents to choose a diaper that is not only completely safe for their little one, but also produced with care for the environment. We are very proud to be one of the first to introduce a recyclable diaper packaging - and we know it will become a huge success,” says Arne Terp-Nielsen, director of Abena Produktion.
Bambo Nature high-quality, ultraabsorbent diapers feature raw materials and ingredients that are carefully selected and controlled. The recyclable paper packaging makes the product even more sustainable, according to the company.
“Developing and sourcing alternative materials for packaging has been challenging but rewarding. Drylock has been actively exploring and investing in alternatives to fossil-based materials, prioritizing for renewable and sustainable sources,” Hommez adds. “For instance, integrating recycled materials into packaging reduces the demand for virgin resources, supports the recycling industry, and advances circular economy goals.”
Drylock is positioning itself among the first to offer a complete menu of sustainable packaging solutions and offers customers several paper solutions or plastic bags with high percentages of recycled material including mechanical or advanced recycled material.
Drylock’s commitment to innovation is rooted in co-development with packaging and machinery partners, built on trust, coinvestment, and a shared long-term vision, Hommez adds. A notable collaboration involved working with suppliers to secure a reliable supply of recycled materials. By guaranteeing volumes of recycled materials, Drylock has helped stabilize the supply chain, encouraging investments in recycling capacity despite fluctuations in virgin material costs.
Drylock’s sustainability vision underscores the importance of taking action today for a better tomorrow, with a continuous focus on research, investment, and execution to achieve meaningful results. Key drivers behind these efforts include trend analysis, consumer demand, and a steadfast commitment to environmental stewardship. This approach aligns closely with the values and needs of today’s customers, who consistently express positive feedback and appreciation for Drylock’s leadership in driving sustainable innovation in the market.
Beyond packaging, Drylock addresses factors such as product composition, pack count, and pallet logistics based on life cycle analysis to maximize impact. This integrated approach ensures that Drylock remains at the forefront of sustainable innovation and market leadership in environmental responsibility.
Plastic waste in diapering is a huge problem. The vast majority of disposable diapers are constructed with two water bottles worth of plastic and sold in single packs with virgin plastic packaging. In fact, about 36% of all plastic is used for packaging, and 85% of it ends up in the landfill, where it can take up to 500 years to break down (source: UN Environmental Program).
“Dyper’s new product line represents a significant step forward in our mission to reduce plastic waste and build a healthier planet for our children,” says Sergio Radovcic, founder and CEO of Dyper. “Parents shouldn’t have to choose between their baby’s well-being and the environment. By using materials such as paper, natural wax and clay in our packaging and plant-based materials in our diapers, we hope to set an industry-wide example that we can all reduce our reliance on plastics as a society.”
This launch marks Dyper’s successful transition to fully recyclable paper packaging for single packs in retail stores – a first of its kind for the category in North America. Packaging for Dyper’s larger Club Boxes is also fully recyclable, with inner packs utilizing post-consumer resin (PCR). Repurposing old plastics that would otherwise have gone to the landfill is central to driving the circular economy and a reduced carbon footprint. Additionally, Club Boxes and inner packs are now certified by the How 2 Recycle labeling program, which clearly communicates recycling instructions to the public.
“Ecolab’s focus on sustainable solutions, deep scientific expertise and broad industry relationships makes them an excellent addition to Paptic’s owner base, providing business opportunities for both companies,” says Tuomas Mustonen, Paptic CEO and co-founder.
“We are excited about the opportunity to support circularity through our investment in Paptic and its successful approach to sustainable packaging,” says Luis Pereira, senior vice president and general manager of Ecolab’s Nalco Water Paper division. “Our shared vision of protecting our planet and its vital resources serve as a foundation for this relationship. Ecolab’s expertise and broad offerings, combined with our global reach, will also help to expand Paptic’s opportunities for growth.”
Paptic Ltd was founded in 2015 to address a significant global environmental challenge—the plastic waste accumulating in the environment. The company developed the Paptic product line, a fiber-based, recyclable material to replace plastics in packaging. With material delivered to over 50 countries worldwide, Paptic aims to increase its global impact through its relationship with Ecolab and other investors.
By utilizing recycled plastic, the buckets aim to avoid taxes on single-use plastic packaging as mandated in Spain and the U.K., with Italy introducing its own in July.
Dr. Lisa Marholt, product manager at SCRUBS supplier ITW Industrial Solutions, comments: “For circular economy to work, three conditions must be met: firstly, the basic material must be recyclable, secondly, the recycled plastic must find buyers, and thirdly, the product made from recycled plastic must itself be recyclable again – we have taken all this into account with our new SCRUBS buckets. By converting our total production, we make it particularly easy for our customers, as everyone then automatically benefits from the increased sustainability.”
Packaging waste reduction has been a part of these efforts. Last year, the company introduced the first-ever Kotex paper pouch packaging and has developed packaging for Huggies Eco Protect diapers with 30% recycled materials in Peru. The bags contain post-consumer recycled content and provide a more sustainable packaging solution for the hypoallergenic diapers made with certified, plant-based fibers.
“A recent Mintel survey shows 39% of Peruvians prefer sustainable packaging, highlighting the importance of the circular economy. By reducing, reusing and recycling materials, we can minimize waste and protect our planet,” says Carolina Gormezano, Huggies’ marketing director for the Andes region.
In 2023, Ontex increased the share of recycled content in its plastic packaging to 20%. It is increasing the recycled content in its plastic packaging with the aim to exceed 30% recycled or renewable content in its plastic packaging by 2025 on top of already having 100% recyclable packaging. Furthermore, by 2025 all of Ontex’s secondary fiber based packaging will contain very high levels of recycled content, greatly reducing the need for virgin fibers coming from trees.
In addition to reducing integrated recycled content into its plastic packaging, Ontex has significantly reduced overall plastic consumption. Through targeted initiatives aimed at reducing the thickness of bags across all product categories throughout Europe, Ontex has achieved substantial reductions in its use of plastic. In 2023, these efforts culminated in a remarkable reduction of 6% compared to 2022, and an even more impressive 11% reduction when compared to 2020. These achievements underscore Ontex’s dedication to diverting from virgin plastics and highlight its proactive approach to minimizing the company’s environmental footprint.
“The launch of our own Woosh diaper, optimized for recycling, is a logical step towards circularity for baby diapers,” says Jeff Stubbe, co-founder and CEO. “Because we have control of both the composition of the product and its processing, we can align the two perfectly. According to the ‘design for end-of-life’ principle, we started at the end and designed a diaper with recycling in mind. Among other things, shifting to mono-materials is an important element of this. We use recyclable plastics such as polypropylene and polyethylene as much as possible. In addition, we avoid materials such as cotton, PLA and PET in the diaper that might disrupt our innovative recycling process.”
In 2021, Woosh began its partnership with Ontex to collect its Little Big Change diapers from nurseries for recycling. Since then, the start-up has expanded its collection effort throughout Belgium. Woosh will recycle its first diapers at a new facility beginning in fall 2024 using a unique recycling process focused on the separation and reuse of the plastic part of the diaper.
Ecorise will be used for the packaging of tennis racquets slated for a rolling global launch starting February 2024.
Yonex is pursuing eco-friendly production as a part of its sustainability efforts, which is seeing the company look to minimize packaging for all sorts of products while keeping a close eye on any impacts on transportation times and quality assurance. For this latest initiative, Yonex is discontinuing the nylon cases it has previously used for its tennis racquets in favor of packaging that uses Ecorise. This will reduce the use of materials made primarily from petroleum-derived plastic.
The use of embossing technology for the Yonex logo, and of ultrasonic welding technology for the production of the nonwoven bags, has also facilitated the creation of eco-friendly packaging that forgoes the use of pigments and adhesives.
Ecorise is a spunbond nonwoven made primarily from polylactic acid (PLA), a plant-derived biodegradable plastic. Ecorise is able to decompose and be composted under certain conditions, and meets standards laid out by a number of domestic and foreign certification bodies, including the U.S.-based BPI, Austrian-based TÜV AUSTRIA (via its certification center in Belgium) and Japanese-based JBPA. This has seen the material receive certifications such as BiodegradablePla and BiomassPla.
“There is no doubt that sourcing more sustainable packaging materials can be challenging. The supply chain for these materials is still evolving. In some regions, supplies are limited and prices are therefore high compared to traditional materials,” says Guido Conio, chief commercial officer, IMA Teknoweb. “But demand is growing, so many new suppliers are entering the market with new solutions: demand is a great driver of innovation. At IMA, we work closely with our suppliers to ensure our customers have access to high-quality, sustainable materials and support them in adapting their processes to use these alternatives without compromising efficiency or product quality.”
As a provider of complete manufacturing lines, IMA has heavily invested in R&D to address challenges related to the machinability of sustainable products. For example, plastic-free wipe materials often have a specific fiber fragility, which can lead to heat sensitivity and breakages during production. To overcome these issues, IMA has equipped its converters with advanced features, including unwinders with tension control, zero-speed splicing, low-friction turning bars, and a multi-step wetting system.
Similarly, machinery specialist GDM has seen some players are now starting to evaluate more sustainable packaging options.
“Regarding consumer preferences, research shows that sustainable packaging is gaining traction among environmentally-conscious buyers, although they still represent a niche within the global disposable products market,” says a GDM spokesperson. “Along with a lack of awareness, the typically higher price of greener products is deterring mass purchases.”
GDM has been testing new packaging options made from 100% non-oil-based green polymers, low-density polyethylene (LDPE), and recycled plastic materials, providing greener alternatives to conventional plastic. For example, the non-oil-based green polymers we use are derived solely from renewable resources like starch. Another example is low-density polyethylene bags, which have a reduced thickness compared to standard ones, allowing for a decrease in virgin polyethylene usage while also contributing to material cost savings.
“Regarding recycled materials, we have been exploring the use of post-consumer resin (PCR)—plastic that has already been recycled and is ready for reuse,” the spokesperson says. “Our bags, made with up to 20% PCR, support a low-carbon circular economy without compromising on quality.
“Additionally, we have successfully introduced mono-material solutions, such as paper bags, which enable easier waste management and faster recycling. Finally, through synergies with Coesia companies, we are now evaluating alternative solutions for secondary packaging as well.
“Alternative packaging materials remain a niche market with relatively low volumes compared to traditional materials, resulting in a limited supply from raw material providers. However, recognizing the growing demand for sustainable options, suppliers have developed innovative solutions to meet industry needs. As interest in eco-friendly packaging rises and government initiatives increasingly drive sustainability, demand for these materials is expected to grow.”
Abena’s Bambo Nature Diapers
Abena is now packaging its eco- and skin-friendly Bambo Nature baby diapers in responsibly sourced FSC-certified paper packaging. The company’s Bambo Nature production site in Denmark can make the new paper diaper packaging material using recycled materials. The packaging is made from Scandinavian FSC (Forest Stewardship Council) certified paper and certified according to industry standards; this means that the packaging can be recycled with normal household paper waste, making it even easier for consumers to be sustainable.“We wish to make it easy and convenient for parents to choose a diaper that is not only completely safe for their little one, but also produced with care for the environment. We are very proud to be one of the first to introduce a recyclable diaper packaging - and we know it will become a huge success,” says Arne Terp-Nielsen, director of Abena Produktion.
Bambo Nature high-quality, ultraabsorbent diapers feature raw materials and ingredients that are carefully selected and controlled. The recyclable paper packaging makes the product even more sustainable, according to the company.
Drylock Technologies’ Sustainable Efforts
As these efforts continue to ramp up on the supply side, hygiene companies are continuing look at reducing packaging waste as a key pillar of their sustainability strategies. Drylock Technologies, which was one of the world’s first hygiene companies to develop paper-based packaging in 2020, has made significant efforts to make its packaging materials more sustainable prioritizing sustainable packaging as part of its commitment to environmental stewardship. The company’s approach focuses on reducing packaging materials, increasing the use of recycled content, replacing fossil-based materials, enhancing recyclability, and lowering their carbon footprint, says Pieter Hommez, R&D manager.“Developing and sourcing alternative materials for packaging has been challenging but rewarding. Drylock has been actively exploring and investing in alternatives to fossil-based materials, prioritizing for renewable and sustainable sources,” Hommez adds. “For instance, integrating recycled materials into packaging reduces the demand for virgin resources, supports the recycling industry, and advances circular economy goals.”
Drylock is positioning itself among the first to offer a complete menu of sustainable packaging solutions and offers customers several paper solutions or plastic bags with high percentages of recycled material including mechanical or advanced recycled material.
Drylock’s commitment to innovation is rooted in co-development with packaging and machinery partners, built on trust, coinvestment, and a shared long-term vision, Hommez adds. A notable collaboration involved working with suppliers to secure a reliable supply of recycled materials. By guaranteeing volumes of recycled materials, Drylock has helped stabilize the supply chain, encouraging investments in recycling capacity despite fluctuations in virgin material costs.
Drylock’s sustainability vision underscores the importance of taking action today for a better tomorrow, with a continuous focus on research, investment, and execution to achieve meaningful results. Key drivers behind these efforts include trend analysis, consumer demand, and a steadfast commitment to environmental stewardship. This approach aligns closely with the values and needs of today’s customers, who consistently express positive feedback and appreciation for Drylock’s leadership in driving sustainable innovation in the market.
Beyond packaging, Drylock addresses factors such as product composition, pack count, and pallet logistics based on life cycle analysis to maximize impact. This integrated approach ensures that Drylock remains at the forefront of sustainable innovation and market leadership in environmental responsibility.
Dyper Uses Paper Packaging
Last year, Dyper incorporated fully recyclable kraft paper packaging into its newly designed diaper products. The paper packaging, which is manufactured in North America—marks a major step forward in both the single-use diaper and packaging industries.Plastic waste in diapering is a huge problem. The vast majority of disposable diapers are constructed with two water bottles worth of plastic and sold in single packs with virgin plastic packaging. In fact, about 36% of all plastic is used for packaging, and 85% of it ends up in the landfill, where it can take up to 500 years to break down (source: UN Environmental Program).
“Dyper’s new product line represents a significant step forward in our mission to reduce plastic waste and build a healthier planet for our children,” says Sergio Radovcic, founder and CEO of Dyper. “Parents shouldn’t have to choose between their baby’s well-being and the environment. By using materials such as paper, natural wax and clay in our packaging and plant-based materials in our diapers, we hope to set an industry-wide example that we can all reduce our reliance on plastics as a society.”
This launch marks Dyper’s successful transition to fully recyclable paper packaging for single packs in retail stores – a first of its kind for the category in North America. Packaging for Dyper’s larger Club Boxes is also fully recyclable, with inner packs utilizing post-consumer resin (PCR). Repurposing old plastics that would otherwise have gone to the landfill is central to driving the circular economy and a reduced carbon footprint. Additionally, Club Boxes and inner packs are now certified by the How 2 Recycle labeling program, which clearly communicates recycling instructions to the public.
Ecolab Partners with Sustainable Packager
To further accelerate its impact in the sustainable packaging space, Ecolab teamed up with a company that manufactures sustainable packaging materials to help them increase the speed and scale of operations. Paptic Ltd, a Finland-based manufacturer of fiber-based packaging materials, has recently started working with Ecolab to expand its material portfolio and make Paptic materials for flexible packaging more widely available around the globe. Ecolab’s direct investment in the company will also support Paptic’s continued growth and focus on their target of carbon neutrality by 2030.“Ecolab’s focus on sustainable solutions, deep scientific expertise and broad industry relationships makes them an excellent addition to Paptic’s owner base, providing business opportunities for both companies,” says Tuomas Mustonen, Paptic CEO and co-founder.
“We are excited about the opportunity to support circularity through our investment in Paptic and its successful approach to sustainable packaging,” says Luis Pereira, senior vice president and general manager of Ecolab’s Nalco Water Paper division. “Our shared vision of protecting our planet and its vital resources serve as a foundation for this relationship. Ecolab’s expertise and broad offerings, combined with our global reach, will also help to expand Paptic’s opportunities for growth.”
Paptic Ltd was founded in 2015 to address a significant global environmental challenge—the plastic waste accumulating in the environment. The company developed the Paptic product line, a fiber-based, recyclable material to replace plastics in packaging. With material delivered to over 50 countries worldwide, Paptic aims to increase its global impact through its relationship with Ecolab and other investors.
ITW Uses Recycled Buckets for Wipes
ITW has transitioned its Scrubs-In-A-Bucket wet wipe range into recyclable plastic packaging. As environmentally conscious and resource-efficient packaging designs become increasingly popular for professional consumables and cleaning agents, a refill pack intended to save plastic was launched on the market last year. Containing 72 wipes, the pack sought to save over 90% of plastic when refilled.By utilizing recycled plastic, the buckets aim to avoid taxes on single-use plastic packaging as mandated in Spain and the U.K., with Italy introducing its own in July.
Dr. Lisa Marholt, product manager at SCRUBS supplier ITW Industrial Solutions, comments: “For circular economy to work, three conditions must be met: firstly, the basic material must be recyclable, secondly, the recycled plastic must find buyers, and thirdly, the product made from recycled plastic must itself be recyclable again – we have taken all this into account with our new SCRUBS buckets. By converting our total production, we make it particularly easy for our customers, as everyone then automatically benefits from the increased sustainability.”
Kimberly-Clark Develops Alternatives
Sustainability also continues to be a top priority for K-C. The company has reduced its plastics footprint by 16.4% toward its goal of a 50% reduction by 2030 over its 2019 baseline. “We’re continuing to develop more sustainable materials—inventing new processes that deliver raw material efficiency (reducing plastic content in our products) and leveraging bio-based resins to reduce environmental impact,” says Lori Shaffer, vice president, Global Research & Engineering, Kimberly-Clark.Packaging waste reduction has been a part of these efforts. Last year, the company introduced the first-ever Kotex paper pouch packaging and has developed packaging for Huggies Eco Protect diapers with 30% recycled materials in Peru. The bags contain post-consumer recycled content and provide a more sustainable packaging solution for the hypoallergenic diapers made with certified, plant-based fibers.
“A recent Mintel survey shows 39% of Peruvians prefer sustainable packaging, highlighting the importance of the circular economy. By reducing, reusing and recycling materials, we can minimize waste and protect our planet,” says Carolina Gormezano, Huggies’ marketing director for the Andes region.
Ontex Increases Recycled Content
Ontex continues to actively work to enhance the environmental profile of its packaging and is poised to significantly strengthen the incorporation of recycled content within its packaging materials.In 2023, Ontex increased the share of recycled content in its plastic packaging to 20%. It is increasing the recycled content in its plastic packaging with the aim to exceed 30% recycled or renewable content in its plastic packaging by 2025 on top of already having 100% recyclable packaging. Furthermore, by 2025 all of Ontex’s secondary fiber based packaging will contain very high levels of recycled content, greatly reducing the need for virgin fibers coming from trees.
In addition to reducing integrated recycled content into its plastic packaging, Ontex has significantly reduced overall plastic consumption. Through targeted initiatives aimed at reducing the thickness of bags across all product categories throughout Europe, Ontex has achieved substantial reductions in its use of plastic. In 2023, these efforts culminated in a remarkable reduction of 6% compared to 2022, and an even more impressive 11% reduction when compared to 2020. These achievements underscore Ontex’s dedication to diverting from virgin plastics and highlight its proactive approach to minimizing the company’s environmental footprint.
Woosh Uses Recycled Packaging
In May 2024, Woosh made another successful step in its mission to create a circular ecosystem for baby diapers by using 100% recycled plastic for both the packaging and water proof innerlayer of its recently developed diapers. The company, which has partnered with Ontex in the collection and recycling of diapers, created a diaper that is both optimized for recycling and contains recycled material. This ties in perfectly with Woosh’s plans to build its own recycling and R&D center in Bruges, Belgium, with the ultimate goal of making the diaper chain circular.“The launch of our own Woosh diaper, optimized for recycling, is a logical step towards circularity for baby diapers,” says Jeff Stubbe, co-founder and CEO. “Because we have control of both the composition of the product and its processing, we can align the two perfectly. According to the ‘design for end-of-life’ principle, we started at the end and designed a diaper with recycling in mind. Among other things, shifting to mono-materials is an important element of this. We use recyclable plastics such as polypropylene and polyethylene as much as possible. In addition, we avoid materials such as cotton, PLA and PET in the diaper that might disrupt our innovative recycling process.”
In 2021, Woosh began its partnership with Ontex to collect its Little Big Change diapers from nurseries for recycling. Since then, the start-up has expanded its collection effort throughout Belgium. Woosh will recycle its first diapers at a new facility beginning in fall 2024 using a unique recycling process focused on the separation and reuse of the plastic part of the diaper.
Yonex Uses Spunbond Packaging
The Ecorise PLA spunbond nonwoven developed by Mitsui Chemicals Asahi Life Materials Co., Ltd. has been adopted as a packaging material for tennis racquets sold by sporting goods manufacturer Yonex Co., Ltd.Ecorise will be used for the packaging of tennis racquets slated for a rolling global launch starting February 2024.
Yonex is pursuing eco-friendly production as a part of its sustainability efforts, which is seeing the company look to minimize packaging for all sorts of products while keeping a close eye on any impacts on transportation times and quality assurance. For this latest initiative, Yonex is discontinuing the nylon cases it has previously used for its tennis racquets in favor of packaging that uses Ecorise. This will reduce the use of materials made primarily from petroleum-derived plastic.
The use of embossing technology for the Yonex logo, and of ultrasonic welding technology for the production of the nonwoven bags, has also facilitated the creation of eco-friendly packaging that forgoes the use of pigments and adhesives.
Ecorise is a spunbond nonwoven made primarily from polylactic acid (PLA), a plant-derived biodegradable plastic. Ecorise is able to decompose and be composted under certain conditions, and meets standards laid out by a number of domestic and foreign certification bodies, including the U.S.-based BPI, Austrian-based TÜV AUSTRIA (via its certification center in Belgium) and Japanese-based JBPA. This has seen the material receive certifications such as BiodegradablePla and BiomassPla.
