By: Dr. Muhamad Hafiz Abd Rahim 

Naziruddin Mat Ariffin^1*, Anis Nabilah Junaidi¹, Muhamad Hafiz Abd Rahim¹

¹Department of Food Science, Faculty of Food Science and Technology, Universiti Putra Malaysia

*The main writer is a PhD student in Food Safety and Quality

In recent years, the detrimental impact of non-biodegradable plastics on the environment has become widely recognised. As consumers grow increasingly eco-conscious, major corporations are exploring ways to make their operations more sustainable. One prominent initiative is replacing traditional plastic packaging with fibre-based materials derived from wood, agricultural residues, or recycled paper (Figure 1). But is this shift truly a solid environmental solution, or could it sometimes be more of a green-washing strategy?

Figure 1: Biodegradable fibre-pulp food trays and bowls made from recycled plant fibres – an example of fibre-based packaging in foodservice. Photo courtesy of Harvest Plastic (https://www.have-pack.com/collections/green-collection-5 )

In our view, fibre-based packaging can present a promising alternative to plastic, but its viability hinges critically on two main considerations: safety (especially for food contact) and sustainability of production.

Sources of fibre and safety concerns

Fibre-based packaging can be sourced from virgin fibres (fresh pulp from trees or plants) or recycled fibres (used paper and cardboard). Each stream has its own safety and sustainability implications.

• Virgin fibre may harbour residual contaminants from pulp production (bleaching agents, adhesives) if not properly processed.
• Recycled fibre often originates from printed papers and cartons. The de-inking and bleaching processes can involve chemicals that, unless carefully controlled, might leave residual migration risks in food-contact packaging. For example, a study by Naziruddin et al. (2021) reported that residual formaldehyde levels in recycled kraft-fibre trays exceeded the European Commission migration limit of 15 mg/kg (Naziruddin et al., 2021). Without a comparable regulation in Malaysia, the monitoring of such packaging safety becomes more ambiguous.

Production sustainability – the hidden costs

The environmental narrative for fibre-based solutions often emphasises renewability and recyclability, but production impacts must also be accounted for. Biobasedpress notes that while paper is made from renewable materials and is generally more biodegradable, its production nevertheless uses significant water and energy, and fibres still need renewal after multiple recycling cycles (BioBasedPress, 2025).  A study applying a cradle-to-grave Life Cycle Assessment (LCA) found that under certain conditions, fibre-based packaging may not always outperform plastic in terms of environmental footprint if transport, water use, chemical treatments, and end-of-life are factored in (Artifelli et al., 2024). 

Potential benefits of fibre-based packaging

That said, fibre-based packaging offers some clear advantages. For example:

• Many paper and board materials have recycling rates above 80%, significantly higher than many plastic streams (Heidelberg, 2025). 
• Fibre materials are derived from renewable sources (trees, agricultural residues) and can fit more readily into circular-economy models (Nefab, 2022). 
• Improvements in design (e.g., thinner board, optimised geometry) plus advancements in coatings and barrier technologies are increasing their suitability for food and beverage packaging (Fofana, 2024). 

It’s not yet the ultimate alternative

However, concluding that fibre-based packaging is a silver bullet would be premature. Key challenges remain:

• Barrier performance: Many food applications (especially oils, high moisture foods) require moisture-, oxygen- or grease-barriers that are currently more reliably delivered by plastics or complex multilayers.
• Contaminant risk: As noted earlier, recycled fibre requires chemical processing and may retain undesirable migration substances if not rigorously controlled and regulated.
• Deforestation risk: If virgin fibre demand increases without sustainable forest management, then supply chains may contribute to deforestation.
• Energy & water consumption: Some LCAs show that producing paper bags or fibre packaging may require more energy and water than equivalent plastic bags – a case reported by the Northern Ireland Assembly in 2011 (Bell, 2011).
• End-of-life behaviours: While paper is often easier to recycle or compost, if fibre-packaging is coated with non-recyclable liners or ends up incinerated/landfilled, the sustainability gains are reduced.

Navigating the greenwashing pitfall

Given these complexities, there is a risk that companies might adopt fibre-based packaging simply as a marketing label, rather than as a genuinely more sustainable solution. The key will be transparency in the full life-cycle impacts, verified certifications (e.g., FSC/PEFC for wood-origin, recyclability audits) and clear communication to consumers.

Concluding thoughts

In conclusion, fibre-based packaging holds strong potential as a more environmentally-friendly alternative to conventional plastic packaging, especially when sourced responsibly, processed with minimal chemical input, and incorporated into well-designed recycling systems. But it is not yet the definitive “ultimate alternative”. A level of caution and diligence is required: as consumers and researchers, we should scrutinise claims, demand full-life-cycle evidence, and resist the temptation to accept “green” as a catch-all label. Only then will fibre-based packaging truly shift from marketing rhetoric to meaningful sustainability innovation.

 

References

• Arfelli, F., Roguszewska, M., Torta, G., Iurlo, M., Cespi, D., Ciacci, L., & Passarini, F. (2024). Environmental impacts of food packaging: Is it all a matter of raw materials?. Sustainable Production and Consumption, 49, 318-328.

• Bell, K., & Cave, S. (2011). Comparison of environmental impact of plastic, paper and cloth bags (Research and Library Service Briefing Note 36/11). Northern Ireland Assembly.

• Biobasedpress. (2025). Why is paper packaging better for the environment than plastic. 24 Apr 2025.  https://www.biobasedpress.eu/2025/04/why-paper-packaging-is-better-for-the-environment-than-plastic/
• Heidelberger, Fiber-based packaging. https://www.heidelberg.com/global/media/fr/global_media/yourbusiness/packaging_/paperization/335414_Whitepaper_Lobbypaper_Pro_Faltschachtel_EN_Web.pdf
• Naziruddin, M. A., Jawaid, M., Yusof, N. L., Abdul-Mutalib, N. A., Ahmad, M. F., Sanny, M., & Alzahari, A. (2021). Assessment and detection of the potential contaminants from oil palm empty fruit bunch fiber-based biodegradable tray. Food Packaging and Shelf Life, 29, 100685.
• Ncube, L. K., et al. (2020). Environmental Impact of Food Packaging Materials. Foods, 9(10), Article 1474. 
• Fofana, O (2024). Paperisation: shifting from plastics to fibre-based packaging. https://www.packaging-gateway.com/features/paperisation-fibre-based-packaging/
• Nefab. (2022). Why fibre-based packaging is a solution for sustainable supply chains.  https://www.nefab.com/news-insights/2022/why-fiber-based-packaging-is-a-solution-for-sustainable-supply-chains/

Date of Input: 31/10/2025 | Updated: 31/10/2025 | nur_jasni