Plastic-Free Packaging: Why it Matters and How to Make the Switch

You’ve probably noticed a growing number of businesses, maybe even your competitors, transitioning to plastic-free packaging. It’s not just a trend, it’s a meaningful shift towards sustainability and customer alignment.

In this blog, we’ll explore:

• Five problems with plastic packaging
• The benefits of switching to paper-based packaging, plus real examples of sustainable alternatives
• Practical steps to help your business make the switch 

5 Problems with Plastic Packaging

Plastic has long been the go-to for packaging, but it comes with drawbacks. Here’s why it might be time to rethink it.

1. Product Damage

The primary purpose of packaging is to protect your products during shipping and storage. But many types of plastic packaging, like plastic bubble, fall short in long-term performance.

One major issue is compression. Plastic-based packaging tends to flatten under the weight of stacked items or prolonged pressure. As it loses its form, it also loses its protective ability. This can lead to: 

• Product damage
• Increased returns and replacement costs
• Poor customer experiences
• Negative reviews
• Lost revenue and profitability

2. Overpacking

Another drawback of plastic packaging is its tendency to lose cushioning effectiveness over time. To compensate, businesses often use more material than necessary in an effort to prevent damage. This overuse not only drives up material and labor costs, but also creates unnecessary waste. 

3. Environmental Impact 

What happens to all that plastic packaging once it’s no longer needed? Most of it winds up in landfills, where it takes anywhere from 10 to 1,000 years to break down. And as it degrades, it releases harmful chemicals into the soil and water.

While many plastic packaging products are labeled “recyclable,” most require specialized recycling facilities that aren't widely accessible. As a result, the majority of plastic waste is tossed in the trash. 

4. Out of Step with Consumer Expectations 

Consumers today, especially younger shoppers, are aware of the effects of plastic packaging on the earth. Many actively avoid brands that rely on plastic packaging and instead support companies using sustainable, eco-friendly materials.

In fact, recent surveys confirm that a significant portion of consumers are even willing to pay more for products that come in environmentally responsible packaging. Ignoring this shift doesn't just risk bad optics, it can mean losing customer trust and revenue to more forward-thinking competitors. 

5. Risk Compliance with Global Regulations

Sustainability regulations are rapidly evolving, particularly in Europe. The European Union has already begun phasing out non-sustainable packaging, and more global regions are expected to follow.

Businesses that continue using plastic packaging risk falling behind, not just in regulatory compliance, but in how they’re perceived by global customers and partners. 

Paper-Based Packaging Alternatives

Fortunately, there are plastic-free alternatives that address the issues discussed above. While materials like mushroom-based foam and sugarcane packaging exist, paper-based solutions strike the best balance of performance, cost, and protection, making them a smart choice for businesses that need practical, scalable options. 

Superior Cushioning

Paper-based packaging materials, such as HexcelWrap® for product wrap and HexaFil™ for void fill, outperform traditional plastic bubble by providing cushioning that doesn’t compress over time. These materials maintain their protective properties, thanks to HexcelPack’s patented slit paper technology, which transforms flat paper into a durable 3D honeycomb structure.

The same material is used for HexcelStretch™, a paper-based pallet wrap that provides stronger load stability with less material. It not only protects your shipments more effectively but also reduces the risk of damage during transport and handling.

Need to ship smaller fragile items like electronics, jewelry, or medical components? Hexcel’Ope™, a paper-based padded mailer, delivers high-performance protection with no plastic necessary. 

Sustainable Packaging 

Every HexcelPack product is designed with the planet in mind. But what defines sustainable packaging? It’s not just about being plastic-free, it’s about meeting real sustainability standards:

• It’s made from responsibly sourced, renewable materials.
• It’s curbside recyclable. No special drop-off or facilities required.  
• It’s manufactured with a reduced carbon footprint and minimal environmental impact.
• It’s free from harmful chemicals or substances that could be unsafe to breathe or touch.

Appealing to Today’s Consumers

Paper packaging is not only effective at protecting products, it also aligns with the values of environmentally conscious customers. Choosing sustainable materials shows your commitment to reducing plastic waste and helps build trust with buyers who prioritize eco-friendly brands.

It also positions your business ahead of tightening international regulations, many of which are moving quickly toward stricter sustainability standards. By switching now, you’re not just meeting expectations, you’re future-proofing your packaging strategy.

How to Make the Switch to Sustainable Packaging

Transitioning to plastic-free packaging is pretty simple. Here are three steps to guide the shift:

Identify Your Packaging Needs and Paper-Based Alternatives

Start by identifying the types of packaging your business currently uses, then explore paper-based alternatives that match your needs. This is also a good opportunity to reassess how much packaging is truly necessary to keep your products protected.

HexcelPack’s paper-based solutions often require less material to achieve better results. With superior cushioning performance, they can reduce the need for excess padding and even allow for smaller shipping boxes, saving you money on materials and shipping costs, whether you're billed by weight, volume, or both.

Evaluate Your Dispensing Systems

HexcelPack offers both manual and automated dispensers, and many of our customers find that a combination of both delivers the best results depending on their packing environment.

While automation has advantages in high-volume operations, manual dispensers remain a popular choice due to their simplicity and speed. In fact, many businesses are returning to manual systems because they’re reliable, intuitive, and require minimal maintenance or training. Here’s a quick breakdown of the benefits.

Benefits of Manual Dispensers:

• No power source required
• Easy to use with little to no training
• No wearable parts, reducing maintenance costs
• Faster for many packing stations due to simplicity
• Flexible for a variety of product sizes and workflows
• Lower upfront investment

Benefits of Automated Dispensers:

• Cut-to-length features reduce waste by dispensing only what’s needed
• Three programmable settings ensure consistent, accurate cuts
• Push-button and foot pedal controls offer hands-free operation

Whether you’re packing individual boxes or palletized loads, HexcelPack will help you find the right setup for your operation—manual, automated, or a blend of both. We can also develop 
customized dispensing solutions tailored to your workflow. 

Tell Your Customers About the Change

Once you’ve made the switch, don’t keep it a secret. Many customers will appreciate your commitment to reducing plastic waste. Others may be curious and open to learning more about sustainable packaging. Use channels like newsletters, emails, product inserts, and website updates to tell your sustainability story and highlight the benefits of your new packaging. 

HexcelPack Will Help You Make the Switch to Plastic-Free Packaging

Ready to move toward plastic-free packaging? HexcelPack is here to support you every step of the way. Our team will evaluate your current packaging setup and recommend tailored, sustainable solutions that protect your products and reduce waste.

Want to see the difference for yourself? Send us a sample of your product, and we’ll wrap, pack, and ship it back using our materials so you can experience the protection firsthand. Reach out today to get started.