Sustainable print reduces packaging plastic by replacing plastic components with printed, paper-based alternatives and using inks and coatings that keep those packs recyclable. Many things once made from plastic, such as wraps, sleeves, windows, trays and secondary packaging, can now be produced in certified board and paper that prints well and recycles easily. It is not a total swap for every use, but for a large share of packaging it is a realistic move.
If you are under pressure to cut plastic, this is a practical and honest look at what printed packaging can and cannot replace, what sustainable inks and coatings add, and the trade-offs to plan for so you reduce plastic without losing quality.
Why brands are cutting plastic from packaging
Brands are cutting plastic from packaging because of customer expectation, regulation and cost pressure, and the three are pushing in the same direction. Shoppers increasingly judge a brand by its packaging, regulation on plastic and packaging waste continues to tighten, and plastic reduction has become a visible marker of whether a brand's sustainability claims are real.
There is a commercial upside too. According to Carbon Balanced Paper, 66% of global consumers say they are willing to pay more for sustainable brands (Nielsen), and 55% of young people in the UK say they would be more loyal to a brand reducing its carbon footprint (Carbon Trust) (Carbon Balanced Paper). Cutting plastic is both a responsibility and a way to strengthen the brand.
How paper-based and printed packaging replaces plastic
Paper-based and printed packaging replaces plastic by taking over the jobs plastic used to do, using certified board and paper that can be printed, formed and recycled. In many formats, the switch is straightforward once the pack is designed for it.
Common replacements include:
- Paper wraps and bands in place of plastic shrink wrap for multipacks.
- Board sleeves and cartons instead of plastic trays and clamshells.
- Paper-based windows or window-free designs replacing plastic film windows.
- Moulded or corrugated paper inserts in place of plastic protective packaging.
- Printed board secondary packaging replacing plastic outers and film.
Printed board also carries branding and information better than plastic, so replacing plastic can improve the pack's shelf presence at the same time. B&B Press produces paper-based and printed packaging through custom printed packaging.
What sustainable inks and coatings add
Sustainable inks and coatings let printed packaging perform like conventional packaging while staying recyclable, which is what makes plastic replacement viable rather than just well-meaning. The substrate does much of the work, but the ink and coating decide whether a pack looks good, holds up, and can still be recycled.
Sustainable options can provide grease resistance, moisture resistance and durability that used to require plastic lamination, using water-based or recyclable-friendly coatings instead of plastic films that block recycling. Efficient curing helps too: B&B Press installed the first LED UV press in the UK in 2014, and LED UV uses roughly 20% less ink and around 95% less power than conventional curing, while cutting drying energy sharply per sheet. The result is packaging that performs and recycles, produced more efficiently.
The trade-offs to be aware of (barrier, durability and cost)
Be honest about the trade-offs: paper-based packaging does not match plastic on every barrier property, and some switches need testing before they work at scale. Pretending there are no limits is how plastic-reduction projects fail.
The main things to plan for:
- Barrier performance. Plastic is very good at keeping out moisture, grease and air. Paper with the right coating can match many uses, but high-barrier needs (some food and liquid applications) require careful specification or may not fully switch yet.
- Durability. For heavy or wet-handling products, board must be specified to cope, which can mean a heavier or coated stock.
- Cost. Some sustainable materials cost more per unit, though this is often offset by customer preference, brand value and, in some cases, avoided packaging tax.
- Recyclability of the final pack. Adding a coating to solve a barrier problem can harm recyclability if you pick the wrong one, so the whole pack has to be judged, not each part.
The way to manage all of these is to test early and involve your printer in the design, so the material, coating and format are chosen together.
How to move to lower-plastic packaging without losing quality
Move to lower-plastic packaging in stages, starting with the easiest wins and testing as you go, so quality and performance are never in doubt. Trying to switch everything at once is where quality problems appear.
A sensible sequence:
- Audit your packaging and identify plastic components that already have proven paper-based alternatives, such as outers, sleeves and wraps.
- Switch those low-risk items first, and confirm they hold up in real handling and transit.
- Work with your printer on the harder items, testing barrier and durability before committing.
- Choose recyclable coatings and keep packs to as few materials as possible.
- Measure and balance the remaining carbon, so the pack's full footprint is accounted for.
|
Plastic packaging |
Sustainable printed packaging |
|---|---|
|
Strong barrier, but hard to recycle in many forms |
Recyclable when designed and coated correctly |
|
Limited surface for high-quality print |
Excellent print and branding surface |
|
Under growing regulatory and customer pressure |
Meets customer and regulatory expectations |
|
Often fossil-based material |
Certified, responsibly sourced paper and board |
|
Carbon rarely addressed at point of order |
Carbon shown at quoting and balanced at no extra cost |
|
One-size default |
Specified per use, with trade-offs managed openly |
How the B&B Press approach fits
B&B Press helps brands cut packaging plastic without guesswork, by combining printed and paper-based packaging, sustainable inks and coatings, and honest advice on where a switch will work and where it needs testing. As a family run printer with over 60 years of experience, FSC certified paper and Carbon Balanced Print, B&B Press can help you replace plastic where it is realistic, keep quality high, and balance the carbon of what you produce.
FAQ
Can printed packaging replace plastic?
In many cases, yes. Paper and board can replace plastic wraps, sleeves, trays, windows and outers when the pack is designed and coated for the job. Some high-barrier uses still need careful specification or may not fully switch yet.
Are paper-based packs recyclable?
They can be, and usually more easily than plastic, if they use recyclable coatings and avoid bonding paper to plastic film. The whole pack needs to be designed for recycling, not just its individual parts.
What are compostable coatings?
Compostable coatings are surface treatments designed to break down in composting conditions, used to give paper packaging grease or moisture resistance without a plastic film. Their suitability depends on the product and on the recycling or composting facilities available, so they should be specified with your printer.
Does removing plastic increase cost?
Sometimes the per-unit material cost is higher, but this is often offset by customer preference, stronger brand value and, in some cases, avoided packaging tax. Costs depend on the material, coating and format, so it is worth pricing specific swaps rather than assuming.
Cut plastic from your packaging
See how paper-based and printed packaging works at B&B Press on the Custom Printed Packaging page, or request advice on where you can realistically reduce plastic.
