BROUGHT TO YOU BY PMMI MEDIA BRANDS:
2026
Edition
Sustainable Packaging
Innovations Report
From The Editors
Welcome to the 2026 Packaging World/Healthcare Packaging/ProFood World Innovations Report.
This second-year report showcases standout packaging and processing equipment and materials spotted by PMMI Media Group editors at PACK EXPO Las Vegas, held September 29–October 1, 2025.
Editors highlight the defining features of each new product and capture videos of the innovations in action on the show floor. What follows is an organized, category-by-category look at the most noteworthy and genuinely new solutions drawn from hundreds of booth visits, and curated through decades of combined editorial experience.
Participating editors included:
- Matt Reynolds, Chief Editor, Packaging World
- Liz Cuneo, Editor in Chief, Healthcare Packaging
- Derrick Teal, Editor in Chief, ProFood World
- Anne Marie Mohan, Senior Editor, Packaging World
- Lilián Robayo Páez, Editor in Chief, Mundo EXPO PACK
- Silvia Gamba, Assistant Editor, Mundo EXPO PACK
- Casey Flanagan, Associate Editor, ProFood World
- Sean Riley, Editor in Chief, OEM Magazine
- Pat Reynolds, Contributor, Packaging World
- Rick Lingle, Contributor, Packaging World
Sustainable Packaging
Introduction
Striving For Sustainability
Explore the latest advancements in sustainable packaging materials—ranging from biodegradable polymers and recycled-content substrates to fiber-based alternatives—and examines how machinery technologies are adapting to process these materials efficiently. From energy-efficient equipment and modular machinery designs to closed-loop production systems and digital optimization tools, the integration of sustainability into both materials and machinery is transforming the entire packaging value chain.
Sustainable Packaging
Innovations Report
Equipment
Sustainable / Recyclable
For Smaller Companies
Operator Friendly
Small Footprint
Allen Field
Recyclable Handles Applicator
Single-stream Ready
This semi-automatic system applies paper handles to folding cartons, enabling single-stream recycling and reducing plastic components in packaging.
Material Versatility
Compatible with paper, fabric, or bamboo handles, this machine makes high-volume handle styles accessible for smaller production runs in mid-market packaging.
By automating a task once reserved for large-scale lines, this system allows mid-range producers to adopt recyclable packaging methods with minimal operational change.
Silvia Gamba
Assistant Editor, Mundo EXPO PACK
Recyclable Handles Applicator
Allen Field
Allows single-stream recycling by replacing plastic handles with paper ones, ensuring the entire carton can be processed together in recycling facilities.
Recyclable Handles Applicator
Allen Field
Key Features
Operators simply slide the carton through for automatic paper handle application, streamlining production across multiple formats. Previously limited to high-volume runs such as wine, detergent, or litter boxes, this semi-automatic system now makes it feasible for smaller operations.
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BEGIN SPONSORED CONTENT
Altor
Sustainable Solutions by Altor
Caring for precious goods and the planet
Altor provides a variety of regenerative solutions at the intersection of trusted performance, next-level sustainability, and seamless integration into existing operations. Sustainability without sacrifice!
Rational Shapes Structural Packing
100% PCR, 100% recyclable, and using 25% less warehouse space, let us optimize your structural packaging!
EmeraldPak Recycled EPS
Predominantly recycled content EPS for thermal and mechanical protection. The proof is in the product!
Hybrid Solutions
Trusted performance, added recyclability. Bead-level recycled EmeraldPak plus warehouse optimizing Rational!
END SPONSORED CONTENT
Energy Efficient
Operator Friendly
Technology Excellence
Emerson
AI-Driven Air Leakage Detector
Predictive Maintenance
Clear dashboard reveals anomalies over time, enabling proactive maintenance.
Sustainability
Compressed-air leaks are notoriously energy-wasteful.
The AI-Driven Leakage Detector translates raw data into clear business metrics—users can simultaneously see air consumption rates, CO₂ emissions, and cost impacts.
Sean Riley
Editor in Chief, OEM Magazine
AI-Driven Air Leakage Detector
Emerson
AI-Driven Air Leakage Detector
Emerson
Key Features
Easily integrated into modern operations, it moves beyond basic leak detection by combining airflow sensors and AI, enabling users to uncover exactly where compressed-air leaks occur (down to a specific valve slice) rather than relying on visual inspections or acoustic methods.
Technology Excellence
Sustainable / Recyclable
Senzani
U-Seal
Recyclable
Designed to move away from plastic and switch to a fully recyclable cardboard packaging.
High Seal Strength
Ability to pack both dry and wet products with the guarantee of a perfect seal.
By producing your packs from flat blanks, this improves warehouse space management, saves on transport costs and reduces emissions.
Liz Cuneo
Editor-in-Chief, Healthcare Packaging
U-Seal
Senzani
The technology forms, fills, and seals cardboard canisters for the transition from plastic to more sustainable packaging.
U-Seal
Senzani
Key Features
Senzani produces automatic cartoners and case packers and introduces the eco-friendly U-Seal technology. Starting from flat blank, U-Seal can handle different pack shapes, of varying diameter and height.
Sustainable / Recyclable
Technology Excellence
Zerust
ZeCycle
Closed-loop recycling program
Users can recycle used VCI film into new PCR materials to reduce waste and support a circular economy.
With programs like these, companies can take measurable steps toward zero waste goals by incorporating responsible and effective recycling into their operations.
Liz Cuneo
Editor-in-Chief, Healthcare Packaging
ZeCycle
Zerust
Minimize plastic waste by recycling used ZERUST® VCI packaging
Used VCI packaging gets a second life
ZeCycle
Zerust
Key Features
This all-in-one, data-driven recycling solution helps businesses reduce carbon footprint, minimize waste, and track sustainability progress through RecycleMax's advanced waste management platform.
Sustainable Packaging
Innovations Report
Flexible Materials
Sustainable / Recyclable
Amcor Flexibles North America
Amcor Revolution APET Barrier Film
Recyclable
A multilayer thermoform for cheese packaging that can be recycled curbside through the PET stream.
Eco-Friendly
Reduces carbon footprint by 43% and water consumption by 36% compared to conventional structures.
The material represents a meaningful step forward in aligning barrier performance with recyclability, addressing one of the packaging industry’s long-standing sustainability challenges.
Anne Marie Mohan
Senior Editor
Amcor Revolution APET Barrier Film
Amcor Flexibles North America
The barrier forming film allows multilayer thermoforms for sliced cheese, cracker cuts, and other cheese snacks to be recycled curbside with PET.
Amcor Revolution APET Barrier Film
Amcor Flexibles North America
Key Features
Revolution APET provides a sustainable option with features comparable to a multi-material tray, including the same product protection, shelf life, and convenience.
Sustainable / Recyclable
Charter Next Generation
GreenArrow MDO-PE film
Recyclable
A matte-finish, machine-direction-oriented polyethylene film capable of being recycled.
Integrated Finish
Eliminates the need for secondary coatings or overprint varnishes.
By combining a premium matte look with store-drop-off recycling capability, this film gives brands a practical way to achieve shelf appeal without compromising sustainability goals.
Anne Marie Mohan
Senior Editor, Packaging World
GreenArrow MDO-PE film
Charter Next Generation
Machine-direction orientation enhances strength, stiffness, and heat resistance, enabling thinner gauges and greater efficiency in high-speed converting.
GreenArrow MDO-PE film
Charter Next Generation
Key Features
GreenArrow MDO-PE is especially suited for food packaging, pet food, confectionery, labels, and other applications where brands seek to align premium positioning with sustainability goals.
Sustainable / Recyclable
Hood Packaging
Recyclable Pet Food Packaging
Recyclable Bag
Joint venture with Dow yields 100% polyethylene packaging that’s store drop-off recyclable.
High Strength
Structure handles net weights to 35 pounds.
At-store recycling options for packaging take a big step forward with this large format bag.
Rick Lingle
Contributing Editor
Recyclable Pet Food Packaging
Hood Packaging
Growth in at-store drop-off recyclable packaging is driven by monomaterial polyethylene packaging.
Recyclable Pet Food Packaging
Hood Packaging
Key Features
The structural and converting details of a large and complex, 100% polyethylene pet-food bag that’s simple to recycle at store drop-off.
Sustainable / Recyclable
Liveo Research
One material blister (OMB)
Recycle ready
Recyclable in existing streams.
Drop-in solution
The OMB runs efficiently on all standard PVC thermoforming lines without changes.
Sustainability has moved from the margins to the mainstream of pharmaceuticals, with eco-friendly materials now seen as essential to both global health and corporate credibility.
Liz Cuneo
Editor-in-Chief, Healthcare Packaging
One material blister (OMB)
Liveo Research
Shown here is a push-through example.
One material blister (OMB)
Liveo Research
Key Features
The OMB, one material blister, can be made from PP or PET materials to replace PVC and aluminum lidding and can be recycled in streams today.
Sustainable / Recyclable
Copar Smart Packaging
HyperBarrier Paper Packaging
Recyclable
Food-safe, recycle-ready coated paper packaging replaces multilayer plastic packaging.
High Barrier
Heat-sealable nano-composite coating provides high barrier to moisture, oxygen, and oil.
A new barrier breakthrough strengthens paper’s push into plastic packaging territory.
Rick Lingle
Contributing Editor
HyperBarrier Paper Packaging
Copar Smart Packaging
Brands' quest to replace plastic packaging with paper options shows no sign of slowing.
HyperBarrier Paper Packaging
Copar Smart Packaging
Key Features
HyperBarrier coating's key features include protection against oil, moisture, and oxygen while remaining recyclable as paper. HyperBarrier packaging runs on standard packaging machinery.
For Smaller Companies
Sustainable / Recyclable
MultiVac Group
MultiSeal Peel-Reseal System
Integrated Reseal
Developed with Supertape, MultiSeal integrates reseal functionality directly into thermoformed and flow-wrap packages.
Accessible Option
Offers an affordable resealable packaging solution for small to mid-size producers.
The reseal feature shows how smart design can make packaging both practical and sustainable by cutting material use, reducing waste, and keeping products fresher for longer.
Anne Marie Mohan
Senior Editor, Packaging World
MultiSeal Peel-Reseal System
MultiVac Group
MultiSeal makes thermoforms and flow-wraps easy to open, reseal, and store, eliminating the need for consumers to repack products.
MultiSeal Peel-Reseal System
MultiVac Group
Key Features
To create the peel-reseal feature, Multivac integrates an unwind system with a slitting unit that applies the reseal layer to the top film web through the sealing die.
Sustainable / Recyclable
ProAmpac
ButterFresh Parchment
Home Compostable
A wax-free, PFAS-free printed butter wrap that is certified home-compostable by TÜV Austria.
Product Protection
Designed to protect butter, margarine, and other oil-based, solid products.
As more brands and consumers seek compostable packaging, ButterFresh offers a home-compostable option for a category that until now was served only by a material destined for landfill.
Anne Marie Mohan
Senior Editor
ButterFresh Parchment
ProAmpac
The wrap provides excellent grease resistance and dead-fold strength, locking in freshness and reducing air exposure.
ButterFresh Parchment
ProAmpac
Key Features
While it differs from traditional wax-coated wraps, ButterFresh is engineered to maintain the same high performance and smooth runnability on packaging lines.
Sustainable / Recyclable
TC Transcontinental
BOPE Film
New BOPE Line
TC Transcontinental’s new 6.5-m-wide production line runs biaxially oriented polyethylene that can be used for a range of flexible film packaging applications.
Recyclable Film
The film is APR (Association of Plastic Recyclers)-certified and can be qualified by How2Recycle as being store drop-off recyclable.
As EPR regulations come into play, the BOPE film enables recyclable, mono-material packaging while maintaining the strength, barrier performance, and shelf appeal that brands require.
Anne Marie Mohan
Senior Editor, Packaging World
BOPE Film
TC Transcontinental
The film is being used in commercial applications in a range of bag sizes and styles, including Doy and stand-up.
BOPE Film
TC Transcontinental
Key Features
The BOPE film offers high strength, clarity, and heat resistance with good printability and barrier properties, providing a recyclable, monomaterial option for flexible packaging applications that performs like traditional multilayer films.
Sustainable / Recyclable
Tipa
TipaPaper Compostable Barrier Paper
Home Compostable
A selection of home-compostable paper laminates with a natural, paper-like look and feel.
Barrier Performance
Offers barrier protection against moisture, UV, gases, aromas, oils, and grease.
As brand owners and consumers look for paper-based and compostable options, TIPA’s barrier papers offer a sustainable alternative without sacrificing product protection or shelf appeal.
Anne Marie Mohan
Senior Editor, Packaging World
TipaPaper Compostable Barrier Paper
Tipa
TipaPaper three-ply laminates feature white paper on the outside and either a transparent or a metallized barrier on the inside.
Among the applications are salty snacks, confectionery, tea, aromatic herbs, grains, nuts, seeds, dried fruits, dry pasta, cereals, powders, and supplements.
TipaPaper Compostable Barrier Paper
Tipa
Key Features
The metallized film can be used for pillow bags, SUPs, zipper bags, and sachets; the paper with transparent liner can be used for SUPs or sachets. They can be run on pouch machines and on vertical and horizontal form/fill/seal packaging lines.
Technology Excellence
Sustainable / Recyclable
Trioworld
Machine Stretch Film with 30% PCR Content
High-performance film
With the use of this 30% PCR content technology, CPGs not only reduce waste but also lower carbon footprint, close the material loop and drive circularity in plastics.
Cost Optimization
This solution, nominated to the 2025 Technology Excellence Awards, reduces environmental impact without compromising technical efficiency.
This high-performance blown stretch film containing 30% post-consumer recycled (PCR) content, is designed for applications that demand exceptional puncture resistance.
Lilian Robayo
Editor in Chief - Mundo EXPO PACK
Machine Stretch Film with 30% PCR Content
Trioworld
Machine Stretch Film with 30% PCR Content
Trioworld
Key Features
Trioworld´s innovative machine stretch film with 30% PCR content closes the loop by reincorporating recycled material.
Sustainable / Recyclable
Operator Friendly
Weber Packaging Solutions
Linerless Labels
Simplified Operation
Longer rolls of labels mean less time spent threading material into the machine.
Sustainability Advantages
No release liner that needs to be disposed of.
Linerless labels make so much sense from a sustainable packaging perspective, so it’s good to see Weber bringing its solution to North America from its connected divisions in Germany.
Pat Reynolds
Contributing Editor
Linerless Labels
Weber Packaging Solutions
Linerless labels have caught on in Europe, so Weber’s German affiliate should be able to make some headway in the North American market.
Weber plans to build on success its German associates have had as it brings linerless labels to North America.
Linerless Labels
Weber Packaging Solutions
Key Features
No more release liners heading for landfill, and because more labels fit on a single roll, operators can spend considerably less time re-loading fresh rolls.
Sustainable Packaging
Innovations Report
Rigid Materials
Sustainable / Recyclable
Energy Efficient
Paccurate
Packing Control System
Reduces Waste
Paccurate helps shippers make better packaging decisions that reduce waste.
Efficient
It provides complete control over how every order is packed.
Efficient packing saves money, materials, and the environment.
Liz Cuneo
Editor-in-Chief, Healthcare Packaging
Packing Control System
Paccurate
Paccurate works with automation companies, warehouses, etc. with the goal of reducing waste and cost in the supply chain.
Packing Control System
Paccurate
Key Features
The Packing Control System is a cartonization engine that ensures properly packed boxes to reduce cost and waste.
Sustainable / Recyclable
Papacks
Custom fiber molded packaging
Custom packaging
Tailor-made packaging solutions
Fiber Based
Packaging made from molded cellulose fibers.
Once considered too fragile for medicine, fiber-based materials are now reshaping pharmaceutical packaging—offering strength, protection, and a lighter footprint on the planet.
Liz Cuneo
Editor-in-Chief
Custom fiber molded packaging
Papacks
Fiber forms for numerous applications in cosmetics, medical, and pharmaceutical industries. A plant-based coating is possible for barrier protection.
Custom fiber molded packaging
Papacks
Key Features
Fiber molding experts that partner with companies to create fiber based packaging like blister, bottles, and more.
Sustainable / Recyclable
SIG
SIG Dome & DomeMini Aseptic Carton Bottles
Single-serve Carton
Single-serve, bottle-style, aseptic cartons in sizes from 16.9 to 33.8 oz and from 6.1 to 11.8 oz for the Dome and DomeMini, respectively.
Renewable & Recyclable
Made from 75 to 95% renewable materials, the cartons are also fully recyclable.
The cartons hit the sweet spot for today’s beverage consumers, offering shelf-stable, recyclable, and portable packaging that supports healthy, on-the-go lifestyles.
Anne Marie Mohan
Senior Editor, Packaging World
SIG Dome & DomeMini Aseptic Carton Bottles
SIG
All package sizes can be made on the same machine, filling a range of beverages, including high- and low-acid RTD options.
SIG Dome & DomeMini Aseptic Carton Bottles
SIG
Key Features
The cartons are made from 75% paperboard, 20% PE, and 5% foil; the Dome is available in four volumes, the DomeMini in eight; they offer a large billboard space; and they feature a differentiated shape with a centrally located closure for easy pouring and minimal product residue.
Sustainable / Recyclable
Solenis
Eco-friendly Coatings & Additives for Paper
In-line Application
Barrier coatings and additives for paper packaging that are applied in-line during the printing or extrusion process.
Paper Material Flexibility
Can be applied directly to cupstock board, flexible packaging, flat sheet paper, and liners for corrugated.
As more CPGs turn to paper, Solenis’ barrier coatings can be applied in-line, giving brands the needed protection without plastics or loss of recyclability.
Anne Marie Mohan
Senior Editor, Packaging World
Eco-friendly Coatings & Additives for Paper
Solenis
Developed with Heidelberg, the in-line process removes offline coating steps and eliminates plastic-based coatings and wax.
Eco-friendly Coatings & Additives for Paper
Solenis
Key Features
Barrier coating choices include flexo-applied coatings, water-based PHA biopolymer coatings applied via flexo or extrusion, TopScreen water- and bio-wax-based formulations, Contour technology for molded pulp, and others.
Sustainable / Recyclable
TemperPack
Qualified Sustainable Pharma Shipper
Sustainability
Packaging replaces EPS insulation with GreenCell Foam made from starch that cuts plastic waste.
End-of-Life Options
Starch-based insulation that is home- or industrially compostable dissolves in water and can be rinsed down a sink.
Compostable packaging has limited practical uses, but starch-based insulation that replaces single-use, unrecyclable EPS is a smart choice.
Rick Lingle
Contributing Editor
Qualified Sustainable Pharma Shipper
TemperPack
TemperPack compostable packaging addresses regulatory activity that penalizes single-use packaging that ends up as landfilled trash.
The Qualified Shipper Program includes lab report, user instructions, home/industrially compostable insulation, coolants, and corrugated shipper.
Qualified Sustainable Pharma Shipper
TemperPack
Key Features
The Qualified Shipper Program includes ISTA Certified Thermal Transport Lab report, pack-out instructions, compostable insulation, coolants, and an outer corrugated box that’s easily recycled.
Sustainable Packaging
Innovations Report
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Innovations Report
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Innovations Report
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Innovations Report
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Our Editors
Matt Reynolds
Chief Editor
Packaging World
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Anne Marie Mohan
Senior Editor
Packaging World
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Elisabeth Cuneo
Editor in Chief
Healthcare Packaging
Derrick Teal
Editor in Chief
ProFood World
Sean Riley
Editor in Chief
OEM Magazine
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Lilián Robayo Páez
Editor in Chief
Mundo EXPO PACK
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Silvia Gamba
Editor
Mundo EXPO PACK
Casey Flanagan
Associate Editor
Packaging World
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Patrick Reynolds
Contributor
Packaging World
Rick Lingle
Contributor
Packaging World
We'd love to hear your feedback!
editors@pmmimediagroup.com
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