When developing a packaging solution, one of the most critical decisions is selecting the right substrate – the base material that protects, preserves, and presents your product. The choice between paper and plastic substrates carries significant implications for performance, cost, and sustainability.

At Redpack, we’ve worked closely with customers across fresh produce, bakery, meat, and non-food sectors to optimise packaging performance. Whether wrapping in traditional plastic films or exploring alternative substrates, our machines are designed to be adaptable – supporting innovation without compromising efficiency.

Paper-Based Substrates

Paper continues to be a popular choice in industries where shelf appeal and sustainability are key. Benefits include being widely recyclable and in some instances biodegradable; these elements alone help brands showcase their environmental responsibilities and increase how positively they are perceived by eco-friendly consumers. Equally paper-based packaging can provide a more luxurious feel, perfect for helping brands showcase more premium products.

Applications include: Labels, sleeves, pouches, and flow-wrap in low-moisture environments

However, paper does come with several limitations. Performance-wise, it struggles in high-moisture or gas-sensitive environments, which can affect shelf life. Additionally, not all paper packaging is as green as it appears. In some cases, the carbon footprint of paper can be higher than plastic, due to the energy and water resources required for production. Further, certain laminates added to paper for durability or barrier protection can render it non-recyclable, undermining its eco-credentials.

3 key things to consider with paper-based substrates:

1. What is the make up of your product? This will determine what laminates the paper will need to ensure that a switch to paper doesn’t degrade shelf-life or product quality. 
2. Test and trial! Paper based substrates behave differently to plastic, with increased thickness varying tensile strength being just two characteristics. If they are not handled and considered correctly packing speeds can be dramatically reduced and downtime increased.
3. Certain laminates can make paper-based packaging non-recyclable, these need to be considered carefully when looking to deliver a sustainability message to consumers to ensure the reality matches the messaging.

Plastic-Based Substrates

Plastic remains a popular packaging choice thanks to its strong performance characteristics, including durability, flexibility, and barrier protection. However,the increasing focus on environmental concerns and tightening regulations around plastic waste are accelerating the need for brands to explore if not move towards more sustainable and recyclable alternatives.

Applications include: Flow-wrap for fresh food, meat, snacks, personal care items

Plastic-based substrates remain a widely used packaging substrate thanks to its lightweight, durable, and cost-effective nature. Its excellent moisture and gas barrier performance help preserve freshness, extend shelf life, and resistance to physical stress – making it ideal for a wide range of food and non-food products. When assessed per unit, it often has a lower carbon footprint due to its manufacturing efficiency and reduced transport weight –  factors that continue to drive its use across the industry.

 3 things to consider with plastic-based substrates:

1. Plastic packaging is under increasing scrutiny due to its environmental impact, particularly its contribution to landfill waste and ocean pollution. Businesses must consider how plastic materials will be handled at the end of their lifecycle and assess the broader implications on sustainability goals and public perception.
2. Not all plastics are created equal. The sustainability of a plastic substrate can vary significantly depending on the type of resin used. Choosing the right resin is crucial not only for recyclability but also for meeting functional requirements like strength, flexibility, and barrier protection.
3. Even if a plastic is technically recyclable, the local availability of recycling facilities and collection systems can impact whether it is actually processed appropriately. Companies must consider the regional variations in recycling infrastructure and consumer access to waste management systems when selecting plastic substrates, particularly if distributing products across multiple markets.

Making the Right Choice

When choosing between paper and plastic substrates, consider:

• Product Requirements – Shelf life, barrier needs, handling
• Machine Compatibility – Existing equipment and speeds
• Cost vs. Sustainability – Balancing budget with environmental goals
• Consumer Expectations – Brand alignment and visual appeal

At Redpack, our packaging machinery is designed to adapt to substrates ,  helping brands trial and transition toward recyclable, compostable, or mono-material films that align with sustainability targets, without disrupting production. Get in touch to test new substrates or explore the latest flowrap technology.