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In our latest Wrap-Up … The ‘wicked’ problem of packaging. Final EPR rates released. New film combines speed, strength, and safety. Evolution of food packaging. Supermarket faces copycat claims. Summer wrappers that change colour. Greenwashing clamp down is stopped. Edible packaging whets appetites. And more…

For Starters …

Tackling the ‘wicked’ problem of packaging

The UK’s Retail Institute has called for urgent cross-sector collaboration to address packaging's "wicked problem", a system entangled in consumer behaviour, policy gaps, and fragmented infrastructure.

Its Future of Packaging 2025 report urges alignment between industry, government, and academia, with recommendations including strengthening domestic supply chains and standardising recycling systems.

Phasing out complex multi-polymer formats in favour of recyclable mono-materials is a key priority. In food packaging, mono-material PE, PP and mixed PO films are increasingly in demand due to their recyclability and compliance with food safety standards. KM Packaging supports this shift with a range of mono-polymer recyclable lidding films.

Food brands are also piloting reusable formats and smart packaging, reflecting the report’s call for innovation and circular solutions.

The Future of Packaging report emphasises the importance of clear, evidence-based communication to rebuild consumer trust and cautions that lasting progress hinges on coordinated action.

Government releases final EPR fees

The UK government has released the final 2025 base fees and eco-modulation rules for Extended Producer Responsibility (pEPR) and the Recycling Assessment Method (RAM).

Aluminium packaging sees a marked 39% drop in fees, now set at £266 per tonne, while plastic rates have also been revised down to £423 per tonne, from the previously proposed £485.

Under the RAM framework, which assigns materials a “Green”, “Amber”, or “Red” recyclability rating, all “Green” and “Amber” materials will be charged at the same rate during the scheme’s first year. Future years will introduce cost benefits for “Green” materials, funded by higher fees on harder-to-recycle “Red” items.

The finalised 2025 pEPR base fees are:

• Aluminium: £266/t
• Fibre-based composite: £461/t
• Glass: £192/t
• Paper and card: £196/t
• Plastic: £423/t
• Steel: £259/t
• Wood: £280/t
• Other: £259/t

KM Packaging plans to provide tailored insights into how these confirmed rates and classifications will impact its customers.

Setting the future trends

Innova Market Insights’ latest trend report highlights mono-materials, artificial intelligence, and reusable formats as top packaging drivers for the future. The firm cites regulatory pressure and retailer demands as key forces behind simpler, smarter, and more circular packaging innovation.

MEANWHILE …

New film combines speed, strength, and safety

KM Packaging has introduced K-Peel 4G, a new mono-PET lidding film that seals at just 110°C with a dwell time of 0.3 seconds.

The new film is available in thicknesses of 21μm and 25μm (84 & 100 gauge), offering material savings while maintaining strength and performance. It is suitable for ambient, chilled, or frozen foods and is compatible with virgin and recycled PET trays.

K-Peel 4G is also ovenable, anti-fog, and compliant with OM7 migration standards for food safety.

Packaging gets clever and cleaner

Food packaging is evolving through a blend of sustainability and intelligent functions, according to Packaging Gateway.

Key developments include the growing use of bioplastics, mono-materials, and recyclable laminates, which help reduce environmental impact.

Smart freshness labels, such as colour-changing indicators, are being introduced to monitor quality and minimise food waste.

Meanwhile, advances in lighter, barrier-capable films and coatings are keeping packaging efficient, recyclable, and functional. Flexible formats emphasise circularity along with lower material use.

SHOP TALK …

From plastic to pulp

Co-op has replaced plastic trays with fibre-based formats across 16 own-brand lines, eliminating over 115 tonnes of plastic annually.

Made from FSC-certified board with a barrier coating, the packs are fully recyclable at the kerbside and maintain shelf life and product visibility.

Copycat claims stir legal battle

Aldi is facing legal action from Mondelez International, which claims the retailer’s private-label snacks use packaging that closely mimics the look of Oreo, Ritz, Chips Ahoy!, and other well-known brands.

The claim, filed in the US, alleges Aldi’s designs could confuse consumers and damage the value of Mondelez's trademarks.

Refill pilot shows strong returns

A joint refill pilot by Aldi and Ocado, utilising GoUnpackaged’s reuse platform, has achieved a refill rate of up to 57%, with 86% of containers returned without deposit incentives.

Products were delivered in reusable packs, then collected, cleaned, and refilled. The company claim that each vessel replaces five single-use items and is designed to be used over 60 times.

BRAND NEW …

Cool wrappers change colour

Cadbury has launched a summer edition of Dairy Milk in the UK with thermo-reactive wrappers that change colour to reveal bright seasonal graphics when chilled. The campaign aims to boost seasonal engagement and reinforce storage guidance.

The confectionery company is also introducing flexible wrappers made from 80% recycled plastic across its sharing bars in the UK, with messaging on pack to highlight recyclability. The shift is expected to cut virgin plastic use by over 250 tonnes a year and follows earlier trials on multipacks.

Whey to go with cheese

Nestlé is trialling “self-packing cheese” using a biodegradable film made from cheese whey byproducts. The film is directly applied to the product in the Central America trial, eliminating the need for separate containers while preserving freshness.

In Mexico, the food and beverage giant has reported a 93.9% recyclability rate across its plastic packaging portfolio, crediting this progress to local partnerships and redesigns of its packaging. Nestlé is targeting 100% recyclability, with a focus on mono-material formats and clearer labelling.

Hint of a new identity

Walkers has applied for a UK trademark on a redesigned logo, hinting at a potential packaging revamp. The proposed design retains the familiar red banner and yellow disc but introduces pale yellow rays radiating outward, creating a sunburst effect.

LAWS AND ORDERS …

EPR reform call in UK

Trade bodies representing the food, drink, and retail sectors in the UK have co-signed an open letter calling for urgent reform of the upcoming Extended Producer Responsibility (EPR) scheme. They cited unclear timelines, patchy cost forecasts, and lack of business consultation as key flaws.

The letter warns that uncertainty is delaying investment in packaging innovation.

EPR reform draft in US

California has released a new informal draft of its SB 54 Extended Producer Responsibility (EPR) regulations following the state's Governor’s rejection of the previous version in March.

Key changes include removing monthly reporting in favour of annual submissions and abolishing requirements for reuse/refill container standards, material tracking, and source-reduction adjustments.

The revised draft also allows for simpler eco-modulation fees for the first two years and includes exemptions for certain materials, initially capped at two years.

Red light for greenwashing clamp down

The European Commission has decided to withdraw its proposed Green Claims Directive, which aimed to clamp down on misleading environmental marketing.

The legislation would have required companies to verify green claims through independent evidence but faced strong opposition.

SUSTAINABLE TOPICS …

Packaging is good enough to eat

Edible packaging made from seaweed, proteins, and polysaccharides is whetting appetites as a sustainable alternative to plastic, according to a recent article. These formats can be safely consumed or composted and offer functional properties such as antimicrobial effects and food protection.

Cellulose wraps up strong growth

A new forecast projects that the global cellulose film packaging market will grow from £704 million in 2025 to £1.07 billion by 2035, at a CAGR of 4.4%.

Derived from renewable sources such as wood pulp and cotton, cellulose film is gaining traction due to its transparency, breathability, and compostability, particularly in the food packaging industry.

Sustainability is not the priority

A recent survey shows sustainability trails well behind price, quality, hygiene, and shelf life in US consumer packaging preferences. While 33% now rate environmental impact as “very important”, it still ranks only sixth overall.

Shortlist showcases circular solutions

Shortlisted entries for Packaging Europe’s Sustainability Awards include Unilever, Waitrose, Berry Global, and Toppan, with innovations spanning refillables, mono-materials, and barrier coatings. The awards recognise scalable, commercially ready solutions that support waste reduction and circularity.

IN TRAYS …

Smarter sealing solution

Proseal has introduced the XTP Automatic Tray Sealer, designed to meet the needs of medium-volume food manufacturers. The machine handles all main tray-sealing formats, including atmospheric, gas flush, vacuum/gas, and skin pack.

It features airless sealing for improved pack presentation and electric actuators to reduce air consumption. The XTP can seal up to 40 packs per minute or 30 packs per minute with MAP, depending on the tray type and material.

Three for the price of one

Amcor has developed a three-compartment mono-polypropylene tray for ready meals designed to separate proteins, starches, and vegetables while maintaining a 12-month ambient shelf life. The format suits existing filling lines and retains standard wall thickness despite its complex shape.

DATES FOR YOUR DIARY …

• International Conference on Food Packaging Technologies and Applications (ICFPTA): 28-29 July, Zurich, Switzerland.
• Bioplastics: 26-27 Aug, Cleveland, Ohio, USA.
• UK Packaging Expo: 3-4 Sept, Manchester Central.
• PPMA Total Show: 23-25 Sept, NEC Birmingham.
• FachPack: 23-25 Sept, Nuremberg, Germany.
• World Food India: 25-28 Sept, New Delhi, India.
• FRUIT ATTRACTION 2025 | Fair of the fruit and vegetables sector: 30 Sept – 2 Oct, Madrid IFEMA.
• Espacio Food & Service Santiago Expo: 30 Sept - 2 Oct, Santiago, Chile.
• PACK EXPO Las Vegas: 29 Sept - 1 Oct, Las Vegas Convention Centre, USA.
• Responsible Packaging Expo: 30 Sept - 1 Oct, ExCeL London.
• International Circular Packaging Conference: 16-7 Oct, Ljubljana, Slovenia & online.
• Abu Dhabi International Food Exhibition: 21-23 Oct, Abu Dhabi, UAE.
• Eurasia Packaging Fair: 22-25 Oct, Istanbul, Turkey.
• Indagra Food: 29 Oct - 2 Nov, Bucharest, Romania.
• Foodex Saudi: 3-6 Nov, Jeddah, Saudi Arabia.
• Food Tech Dhaka Expo: 20-22 Nov, Dhaka, Bangladesh.
• Agro Pack Iraq Expo: 24-27 Nov, Erbil, Iraq.
• Sustainable Packaging Summit: 10-12 Nov, Utrecht, Netherlands.
• Grüne Woche Berlin: 16-25 Jan 2026, Berlin, Germany.
• Gulfood: 26-30 Jan 2026, Dubai World Trade Centre & Dubai Expo City, UAE.

From the KM team … protecting, presenting, and preserving your products.