Pack.Nxt: Dr NC Saha on the future of packaging

The term sustainable packaging has been a prominent topic over the past decade, drawing increasing attention due to its importance in mitigating environmental issues. In 2015, the United Nations’ World Population Prospects forecasted that the world population would rise to 10.4 billion by 2100, up from 7.2 billion in 2015. This projected population growth raises significant global concerns, particularly concerning the limited natural resources available, such as water, energy, and the oxygen required for respiration. As the global population continues to swell, the scarcity of essential resources like land for habitation, water, energy, and breathable air is becoming an increasingly pressing issue.

As of 2024, the world population stands at 8.2-billion, with India contributing 1.45-billion. By 2030, India’s population is expected to surpass China's, reaching 1.515-billion, making India the most populous country in the world. In 2030, the global population is projected to hit 8.5 billion, with India and China together accounting for one-third of the world’s population.

This demographic shift emphasises the urgent need for sustainable environmental practices, not only to protect the planet but to ensure the resources necessary for future generations. The United Nations defines environmental sustainability as “meeting the needs of the present without compromising the ability of future generations to meet their own needs.” highlighting the necessity of balancing current demands with long-term sustainability.

Within the packaging industry, there are four major materials used: paper, metal, glass, and plastics. Except for plastics, which are derived from fossil fuels, all other materials are sourced from natural resources.

Paper, traditionally made from wood, is now often produced using alternative biomass materials such as bagasse, bamboo, paddy straw, and wheat straw. These materials are cellulosic, fully recyclable, and considered sustainable. However, life cycle assessments (LCA) have highlighted that paper production is highly water-intensive, requiring approximately 100 litres of water to produce just 1 kilogram of paper.

Similarly, glass is made from natural materials like sand, lime, and soda ash and is easily recyclable, but its production is energy-intensive, given that glass melts at temperatures around 1500 degrees Celsius. Metals like tin and aluminium, also sourced from natural materials, require significant energy to be melted and processed.

On the other hand, plastics, which were only developed in 1914, have become the most widely used packaging material over the last century. Their popularity stems from their versatility and cost-effectiveness, but the resulting environmental concerns regarding waste disposal are significant. Plastic packaging waste, especially multilayered and multi-material flexible packaging (MLP), poses a serious challenge for recycling systems. Although plastics—whether in rigid or flexible forms—are easily recyclable, the concern is particularly with MLP, which is more difficult to process due to its complex structure.

Flexible packaging has gained widespread use, especially in the fast-moving consumer goods (FMCG) sector, due to its many advantages, including ease of availability, printability, sealability, and high mechanical and barrier properties. These features enhance the shelf-life of food products, making them a popular choice.

A market study reveals that 71% of consumers prefer flexible materials, and 55% of brand owners use them for FMCG packaging. However, the recyclability of these materials and their contribution to circularity remain a major concern. At present, MLP is being recycled, and the resulting granules are used to produce various utility goods such as compression-moulded plastic boards, flower pots, and materials for road construction. However, these efforts are unlikely to provide a solution for achieving full circularity.

Given the challenges of recycling and waste management, the concept of responsible packaging is proving to be more appropriate than sustainable packaging. Responsible packaging encompasses the collective responsibility of all stakeholders across the value chain, including manufacturers, consumers, and recyclers, to ensure that packaging materials are responsibly sourced, used, and disposed of. This broader approach focuses not just on the materials used, but on the entire lifecycle of packaging. I am personally associated with the Foundation for Innovative Packaging and Sustainability (FIPS), a non-governmental organisation that organises an annual event on responsible packaging. The upcoming Respack-25, scheduled for 12-13 June 2025, will bring together industry experts to discuss and explore the latest developments in responsible packaging.

Alongside these environmental considerations, shifts in consumer behaviour, particularly among younger generations such as Gen Z and millennials, are influencing packaging trends. Changes in lifestyle, including a greater demand for fast foods, increased awareness of health and safety, and the rise of e-commerce, are all contributing to the need for more innovative packaging solutions. Moreover, consumers are becoming more environmentally conscious and increasingly concerned about the sustainability of the products they purchase.

These evolving consumer preferences have sparked a significant demand for new packaging technologies, including what is now known as smart packaging. Smart packaging can be categorised into three main subsets: intelligent packaging, active packaging, and connected packaging. Intelligent packaging incorporates interactive elements, such as digital sensors, displays, barcodes, QR codes, RFID tags, and time-temperature indicators (TTIs), which can provide real-time data on the product's condition.

Active packaging includes elements like moisture absorbers, oxygen scavengers, odour absorbers, and antimicrobial agents, which help to preserve the quality and extend the shelf life of food products. Connected packaging leverages cloud-based technologies to facilitate data processing, tracking, and communication, integrating with the Internet of Things (IoT) to provide additional functionalities, such as social content delivery, inventory control, and logistics tracking.

According to market research, the global market for active, smart, and intelligent packaging was valued at USD 87.24 -billion in 2023, with expectations to grow to USD 169.40-billion by 2032, representing a CAGR of 7.5% between 2018 and 2025.

Active and intelligent packaging is primarily used in food and beverage packaging, pharmaceuticals, cosmetics, and other sectors. Connected smart packaging, on the other hand, is increasingly employed for tracking and traceability, inventory control, and supply chain management.

The upcoming Respack-25 conference, which will address the four key aspects of sustainable, smart, active, and intelligent packaging, promises to be an insightful event. Experts from various industries will come together to discuss the latest trends and innovations, and I believe this event will be highly beneficial in shaping the future of responsible packaging.

In conclusion, the global population growth and the mounting environmental challenges we face today highlight the importance of adopting responsible packaging practices. While significant strides have been made in developing sustainable materials and technologies, the ultimate goal should be to create packaging systems that are both environmentally responsible and capable of supporting a circular economy. The collective efforts of industry players, consumers, and other stakeholders will be essential in driving forward these changes, ensuring that we preserve the planet for future generations.

Dr NC Saha is the founder-chairman of the Foundation for Innovative Packaging and Sustainability; a visiting professor at the Indian Institute of Management, Mumbai; and the former director at the Indian Institute of Packaging, Government of India.