Why is plastic-free food packaging becoming the industry standard in 2026?
Plastic-free food packaging is becoming the industry standard in 2026 primarily because EU regulations now require it. The EU Packaging and Packaging Waste Regulation (PPWR) applies from August 2026, setting binding recyclability, material efficiency, and PFAS restrictions across all 27 member states. For food manufacturers and packaging suppliers, this is no longer a voluntary sustainability choice but a legal baseline. The sections below address the most common questions companies are asking as they navigate this shift.
What regulations are driving the shift away from plastic packaging?
The EU Packaging and Packaging Waste Regulation (PPWR), which applies from 12 August 2026, is the single most significant driver. It replaces a 30-year-old directive with directly binding rules covering the entire packaging life cycle, from material composition to end-of-life. Unlike the directive it replaces, this is a regulation, not a directive, meaning it requires no national transposition and applies uniformly and immediately across all EU member states.
The PPWR introduces several requirements that directly affect plastic-heavy packaging formats. All packaging placed on the EU market must be recyclable at scale by 2030. From August 2026, food-contact packaging containing PFAS chemicals above specified concentration limits cannot be placed on the market at all. PFAS, often called “forever chemicals,” have been widely used as barrier coatings in grease-resistant paper and coated trays for meat, ready meals, and bakery products. There is no grandfathering provision, meaning packaging already manufactured before the deadline is also affected. Jospak’s fiber materials and production processes already meet these strict purity requirements, and the risk from unintentional PFAS residues in recycled fiber is actively managed within our supply chain.
Extended Producer Responsibility rules under the PPWR mean producers now bear financial responsibility for the full life cycle of their packaging, with fees modulated based on recyclability and recycled content. This creates a direct cost incentive to move toward fiber-based and recyclable formats rather than conventional plastic. The regulation also sets binding reuse and minimization targets for certain packaging categories by 2030, adding further pressure on material-intensive plastic formats. For food businesses selling into Central Europe, where environmental scrutiny from retailers and consumers is particularly strong, compliance is both a legal and commercial necessity.
What materials are replacing plastic in food packaging?
Fiber-based materials, primarily paperboard and cardboard, are the leading replacement for plastic in food packaging. They are renewable, widely recyclable, and compatible with modified atmosphere packaging (MAP) when combined with a thin barrier film. Other alternatives include molded fiber, bio-based films, and compostable materials, though these vary in functionality and regulatory acceptance.
The most commercially mature solution for fresh food categories is the fiber-based tray with a barrier film. This structure replaces the bulk of the plastic in a conventional hard-plastic tray while retaining the gas-tight properties needed to extend shelf life. Our Jospak® carton tray, for example, uses at least 85% less plastic compared to a same-sized tray made fully from plastic, while remaining suitable for MAP packaging of meat, fish, poultry, plant-based proteins, and ready meals. The tray is designed for the circular economy: the cardboard and film are separable, allowing valuable fiber to re-enter existing collection and recycling systems in line with the PPWR’s recyclability-at-scale requirement.
The cardboard component is made from renewable wood fiber sourced from sustainably managed forests, and the tray is recyclable as cardboard packaging in most European countries, including Finland, Sweden, Germany, and Poland. The thin plastic film can either be left in place for standard cardboard recycling streams or separated for separate recycling where infrastructure allows. Please note that fiber-based food trays should be recycled as cardboard and do not belong in biowaste. This recyclability without complex sorting instructions is one reason fiber-based trays are gaining ground with retailers and food manufacturers alike.
How does plastic-free packaging maintain food safety and shelf life?
Plastic-free food packaging maintains food safety and shelf life through a hermetic seal and a multi-layer barrier film that controls the internal atmosphere of the pack. The fiber-based tray is sealed with a lidding film, making the package suitable for modified atmosphere packaging, where the oxygen level inside is replaced with a protective gas mixture that slows spoilage and bacterial growth.
The key functional requirement for fresh food packaging is gas tightness, and this is achieved through the barrier film rather than the tray body itself. The cardboard tray provides structure, printability, and the bulk of the material volume, while the barrier layer handles the food-contact and preservation function. This separation of roles means the plastic content can be reduced significantly without compromising the shelf life properties the food industry depends on.
Certifications matter here. Our packaging holds BRCGS Packaging certification with a grade of AA+, the highest possible result under a standard developed specifically for packaging used by food manufacturers and food retailers. The FSC CoC certification independently verifies the origin of the wood fiber raw material. These credentials are not simply marketing signals; they are documented evidence that food safety and supply chain traceability requirements are met at the highest level.
Which food categories are switching to plastic-free packaging first?
Fresh protein categories are leading the transition to plastic-free food packaging. Meat, poultry, and fish are the first movers because they already rely on modified atmosphere packaging, which fiber-based tray formats support directly. Ready meals, plant-based protein products, and prepared salads are also switching quickly, driven by retailer sustainability commitments and consumer preference for fiber over plastic at the point of sale.
These categories share a common characteristic: they are sold in retail environments where packaging appearance, shelf visibility, and material credentials directly influence purchasing decisions. Fiber-based trays offer a large printable surface that supports brand messaging and product information without additional labels or cardboard sleeves, which reduces overall packaging material use and associated costs.
Processed and convenience food categories are following closely. The shift is accelerating in Central Europe, where retailer sustainability policies and consumer awareness of packaging waste are most developed. Industry experience shows that once a major retailer in a market switches its own-label fresh range to fiber-based trays, supplier adoption across that category tends to follow within one to two product cycles.
What does plastic-free packaging mean for production line compatibility?
Plastic-free fiber-based trays are designed to work with existing automatic tray-sealing lines already in use across the food industry. This is one of the most commercially important features of the format: food manufacturers do not need to invest in new packaging equipment to make the switch from hard plastic trays to cardboard tray formats.
Compatibility with current production lines removes the single largest practical barrier to adoption. A food business can transition to a recyclable, fiber-based tray without disrupting throughput, retraining production staff on new processes, or writing off existing capital equipment. The tray dimensions and sealing mechanics are matched to the same automated packaging lines used for conventional plastic trays.
On the manufacturing side, the technology used to produce fiber-based trays has also advanced significantly. Our production machines now use linear motors rather than compressed-air cylinders, bringing operating efficiency up to 90% and delivering more consistent quality across high-volume runs. The Forssa factory is being scaled to produce up to 150 million trays per year across six production lines, providing the supply reliability that large food manufacturers and retailers require when committing to a new packaging format.
How do consumers and retailers respond to plastic-free food packaging?
Consumer and retailer response to plastic-free food packaging is strongly positive. Research consistently shows that fiber-based packaging is preferred over plastic by consumers and increases willingness to pay. Retailers across Central Europe are actively setting targets to reduce plastic packaging across their own-label ranges, making fiber-based alternatives a procurement priority rather than a niche option.
For consumers, the visual and tactile difference between a cardboard tray and a hard plastic tray is immediate. Fiber-based packaging delivers a measurable reduction in plastic use at the point of purchase, which aligns with the values of environmentally aware shoppers. The large printable surface of a cardboard tray also gives brands more space to communicate product origin, preparation instructions, and material credentials directly on the pack, reducing the need for additional printed sleeves or stickers.
Retailers respond to the format both commercially and strategically. Switching to recyclable fiber-based trays helps retailers meet their own Extended Producer Responsibility obligations under the PPWR, where fees are modulated based on the recyclability of packaging. The PPWR’s paper and cardboard recycling target of 75% by 2030 further reinforces fiber-based formats as the commercially and regulatory-aligned choice. Adopting recyclable fiber trays also positions fresh food ranges favorably against the backdrop of growing regulatory and media scrutiny of single-use plastic in food retail. For suppliers, demonstrating readiness to supply plastic-reduced formats is increasingly a condition of ranging discussions with major grocery accounts in Germany, the Netherlands, and the Nordic markets. Companies looking to accelerate this transition can benefit from expert guidance on packaging strategy and regulatory alignment, which is the focus of our sustainability consulting service.
