Plastic films have excellent protective properties that cannot easily be replaced by alternative materials, especially in the food sector. For example, replacing a 70 µm thin composite film with a recyclable mono film would require a material thickness of 1,200 µm in order to achieve an equivalent oxygen barrier - a considerable additional expense with negative ecological consequences.

A comparison with other packaging materials shows that plastic packaging is often more resource-efficient. A study by the Gesellschaft für Verpackungsmarktforschung (GVM - Society for Packaging Market Research) has determined that completely dispensing with plastic packaging would quadruple packaging weight, increase energy consumption by 50 % and double production costs.

Practical examples:

Extended shelf life of food

The retailer Marks & Spencer in the UK introduced special plastic packaging for fresh apples. The modified atmosphere in the packaging extended the shelf life by up to 14 days, significantly reducing food waste. A study showed that this packaging solution saved thousands of tons of unsold apples from being thrown away every year.

Reduction of packaging weight in logistics

A large German shipping company tested alternative packaging materials to reduce its carbon footprint. While cardboard boxes were heavier and bulkier, thinner, durable plastic films led to a significant reduction in the total weight per shipment. This resulted in a fuel saving of 15 % in the transportation sector.

Recycled plastics in the automotive sector

A well-known car manufacturer is increasingly using plastics made from recycled packaging film for the interior of its vehicles. This switch not only reduces dependence on fossil raw materials, but also cuts emissions in the manufacturing process by up to 25 %.

A key factor in the sustainability assessment of plastic packaging is its origin. Polyethylene (PE) and polypropylene (PP), the main components of many packaging films, are created as by-products of crude oil refining. This means that an existing raw material is recycled. In addition, the thermal recycling of plastics enables the substitution of fossil fuels, which also contributes to the conservation of resources.

A key aspect of the current sustainability debate is the recyclability of flexible packaging. There is room for improvement here, as clear parameters for assessing recyclability still need to be defined. Advances in materials research and new recycling processes could significantly increase recyclability and close the loop.

The environmental impact of packaging must be considered in relation to the packaged product. Food loss is one of the main sources of CO2 emissions - the WHO puts it at 4.4 gigatons per year. Highly developed plastic films help to reduce these losses by preserving food for longer and minimizing spoilage.

A concrete example shows the relationship: the production of one kilogram of beef causes around 13 kilograms of CO2 emissions, while the associated packaging only emits 200 grams of CO2. This means that the packaging protects a valuable resource with a significantly higher CO2 footprint than the packaging itself.

A comprehensive analysis shows that, despite all the criticism, plastic packaging is an essential component of sustainable packaging concepts. It protects valuable resources, reduces food waste and in many cases has a better environmental footprint than supposedly more sustainable alternatives such as glass or metal. At the same time, the packaging industry has a responsibility to develop further. Advances in design for recycling, the use of recyclates and innovative material developments offer great potential to further develop plastic as a sustainable solution instead of just seeing it as a problem.