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Paper and Cardboard Packaging: From Cellulosic Substrates to Functional and Hybrid Architectures.

Leonardo Pagnotta1

  • 1Department of Mechanical, Energy and Management Engineering, University of Calabria, Arcavacata, 87036 Rende, Italy.

Materials (Basel, Switzerland)
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PubMed
Summary

Advanced paper packaging uses functional layers to improve barrier properties. However, this can impact recyclability, highlighting the need for design-for-recycling strategies in sustainable packaging development.

Keywords:
barrier propertiescompostabilityconverting compatibilityfood-contact materialsfunctional coatingshybrid packaging systemsmultilayer architecturespaper-based packagingrecyclabilitysustainable packaging

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Area of Science:

  • Materials Science
  • Sustainable Packaging
  • Chemical Engineering

Background:

  • Paper and cardboard are favored for packaging due to sustainability and recyclability.
  • Monolithic cellulosic materials have limitations in barrier performance (porosity, moisture sensitivity).
  • Advanced paper packaging utilizes coatings, multilayers, and hybrid structures to overcome these limitations.

Purpose of the Study:

  • To review the evolution of paper-based packaging from basic substrates to advanced functionalized systems.
  • To analyze the relationship between structural design variables and key performance metrics.
  • To identify strategies for enhancing both performance and circularity in paper packaging.

Main Methods:

  • System-level analysis of scientific and technical literature.
  • Criteria-driven examination of material composition, layer architecture, and interfacial phenomena.
  • Development of a framework linking structural design to performance domains.

Main Results:

  • Functional layers are critical for enhancing barrier properties and mechanical integrity.
  • A key trade-off exists between barrier efficiency and recyclability.
  • Design-for-recycling and controlled delamination are identified as crucial for next-generation packaging.

Conclusions:

  • Advanced paper packaging requires careful design to balance performance and end-of-life management.
  • Optimizing functional layers is essential for achieving sustainable and high-performing packaging solutions.
  • Future research should focus on strategies that promote recyclability alongside barrier enhancement.