The Rise of Eco Innovation in Modern Paper Manufacturing
The demand for paper has changed as a result of the digital revolution, which has also spurred innovation. According to McKinsey study, future growth in the paper and forest products business will be a reflection of economic development, population growth, and growing customer preferences for eco-friendly products.
Consumer packaging will be impacted by demographic changes and consumer preferences including the need for sustainability and convenience, while over the next years, e-commerce will fuel the expansion of transport packaging. This changing landscape is driving pioneering approaches and fresh product diversification that meet the expectations of environmentally conscious consumers.
They include innovative alternatives to:
Pulp fibers: A wide variety of renewable sources can be used including agricultural residues (e.g. straw, corn stalks), grasses (e.g. switchgrass, miscanthus), and fast-growing crops like bamboo and hemp. Moving away from traditional wood fibers helps paper manufacturers reduce their environmental impact. They can also support the production of high quality, environmentally friendly pulp and paper products that meet the increasing consumer demand for sustainable products. Examples include Favini’s Tree Free family that uses bamboo and Shiro Alga Carta conceived as a way to use the damaging algae in the Venice Lagoon, Fedrigoni’s Bamboo WS FSC self-adhesive range, and Antalis’s Curious Particles options.
Plastic: Renewable and biodegradable paper-based packaging offers a solution to the international reliance on single use plastics. The challenge is to create a solution that meets the expected environmental and performance standards. Finland’s Metsä Group has developed its Muoto 3D fibre line, that uses moulded pulp technology to create lightweight, durable packaging solutions. Smurfit Westrock’s Better Planet Packaging Initiative aims to redefine packaging as a sustainable, circular solution, and has resulted in the creation of AgroPaper, a degradable paper alternative to plastic film in agriculture, which can enrich the soil post-use; TopClip, a recyclable alternative to shrink wrap for multipack beverage cans popular among breweries; and paper pallet wrap, a stretchable paper that can replace plastic stretch film in logistics.
Synthetic textile fibers: Dissolving pulp has been developed to replace non-renewable synthetic fibers like polyester and nylon that are made from fossil fuels andused in textiles. Derived from wood cellulose, dissolving pulp can be transformed into regenerated fibers like viscose, lyocell, and modal. Many global pulp and paper companies are expanding their production to meet the textile industry’s demand. Innovations in blockchain technology are also enhancing traceability – a growing priority for the fashion sector. For example, Sappi’s dissolving pulp brand Verve partnered with a key customer on ‘Green Track’ blockchain technology to provide a forest to garment traceability solution. Södra’s OnceMore initiative focuses on the circularity of textile fibers. The industrial scale recycling process combines textile waste with responsibly sourced wood fibers to create virgin quality dissolving pulp. It separates polyester from cotton, reusing the cotton to create OnceMore pulp while incinerating the polyester to generate energy for its operations. Antalis’s Refit also transforms textile remnants into sustainable paper grades.
Advances in the papermaking process itself have resulted in high density papermaking and long-fibre papermaking. The former is ideally suited to applications in packaging and industrial sectors where robust materials are essential, while the latter’s superior printability and aesthetic appeal make it a preferred choice for premium publications and marketing collateral.
Innovations in machine learning have also optimised fiber blending processes, allowing for precise control over paper properties such as strength, opacity, and surface finish. While Nanotechnology is being used to incorporate nanoparticles into paper coatings to improve printability, moisture resistance, and durability. It enables powder fixation processes that reduce the environmental footprint of paper production by minimising chemical usage.
These solutions illustrate how the industry is progressing in many ways to address consumer demand for environmentally responsible solutions.
This is something we at Ricoh are experienced in. Most recently with our development of the High Caliper Media Customisation service for the RICOH Pro C9500 digital colour sheetfed press that enables the production of Green Gift Cards – a highly sustainable, board based, alternative to plastic gift cards. The new press capability also opens doors to high margin applications including luxury business cards, swing tags, and gift card packaging.
Talk to Ricoh and discover the possibilities that can be explored when creative, sustainable, and environmentally responsible substrates are combined with the latest digital printing technology.
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