Overcoming the challenges of paper packaging design

However, the shift to paper isn’t without its challenges. Designing packaging that is not only sustainable but also functional, cost-effective and visually appealing requires careful consideration. Brands must balance product protection with material limitations, meet regulatory standards and find new ways to stand out in an increasingly competitive landscape.

In this blog, we will explore the key challenges of paper packaging design, and, more importantly, the innovative solutions that are helping businesses overcome them. From advanced materials and coatings to expert design strategies and future-focused thinking, we will share practical insights to help your packaging perform better while aligning with your sustainability goals.

The rise of paper packaging: A sustainable shift

As the demand for more sustainable packaging increases, and legislation changes making it necessary, paper packaging is more important than ever. Paper offers advantages such as being renewable, recyclable and biodegradable.

In addition to its environmental benefits, this type of packaging also aligns with changing consumer preferences. More shoppers are actively seeking products that reflect their values, including minimal environmental impact and responsible sourcing. For brands, this shift presents an opportunity to build trust and loyalty through packaging that tells a sustainable story.

This shift in consumer behaviour and regulatory changes come with a responsibility to innovate. It is not enough for packaging to simply be ‘sustainable’, it must also meet the high standards of durability, shelf appeal and performance. This has led to a wave of innovation across the industry, from barrier-coated papers that offer moisture resistance to structural designs that optimise material use without compromising strength.

As businesses navigate these changes, those that embrace creativity, collaboration and smart design thinking will be best positioned to lead.

Key challenges in paper packaging design

With a focus on finding more sustainable packaging, paper is the preferred choice. However, there are some challenges that come alongside paper packaging design, including:

1. Product protection: Compared to plastics, paper may offer less durability and protection. This presents challenges for sensitive items and requires careful design to maintain product safety.
2. Material limitations: Paper is inherently permeable to moisture, air and grease. This makes it difficult to contain liquids or perishable products without additional, and often costly, coatings that can affect recyclability.
3. Cost: Paper can be more expensive than plastic, especially for high-volume production. Costs can fluctuate due to raw material availability and price volatility.
4. Meeting regulatory standards: Meeting evolving regulations for packaging materials, labelling and sustainability requires ongoing adaptation and can be complex.
5. Addressing supply chain constraints: The reliance on raw materials like paper pulp and the need for sustainability certifications can lead to supply chain disruptions.
6. Brand differentiation: Packaging must balance sustainability with the ability to stand out, create an engaging ‘unboxing experience’ and reflect your brand’s values.

With these design challenges in mind, there are many innovative solutions to combat these and to help create packaging that is both functional and sustainable.

Innovative solutions to common paper packaging challenges

While paper packaging presents a number of design and functional challenges, ongoing innovation in materials, processes and strategy is helping brands overcome these obstacles. By leveraging advanced technologies and smart design thinking, it is possible to create packaging that meets sustainability goals without compromising on performance or cost-efficiency.

Some solutions that shape the future of paper packaging design include:

1. Advanced material technologies: New developments in fibre engineering and barrier coatings are improving the durability, moisture resistance and shelf-life capabilities of paper, allowing it to replace plastics in more use cases.
2. Biodegradable coatings: Instead of plastic linings, brands are turning to compostable and biodegradable coatings that maintain product protection while enhancing recyclability and end-of-life sustainability.
3. Cost optimisation through design and material selection: Efficient structural design, minimal use of materials and strategic sourcing help reduce production costs while maintaining packaging integrity and aesthetics.
4. Collaborating with experts: Working closely with packaging experts, like Swiftpak, sustainability consultants and supply chain partners ensures that paper packaging design is both practical and compliant with industry regulations.
5. Educating consumers through clear recycling instructions: Clear, simple messaging about how to recycle or dispose of packaging helps increase consumer participation in sustainability efforts, and reduces contamination in recycling streams.

By embracing these innovative approaches, brands can rise to the challenges of paper packaging design while delivering on environmental, economic and consumer expectations.

Expert tips for designing effective packaging

Creating impactful and sustainable paper packaging requires more than just choosing eco-friendly materials. It is about smart, strategic design that balances functionality, aesthetics and environmental responsibility.

Here are some expert tips to guide your design process:

• Design with the product in mind: Tailor the structure and strength of the packaging to the product’s specific needs. Fragile, heavy or moisture-sensitive items may require reinforced paperboard or innovative inserts for protection.
• Minimise material use: Use only as much material as necessary to protect and present the product. Lightweighting and right-sizing not only reduce costs but also improve sustainability by minimising waste.
• Consider recyclability from the start: Avoid mixed materials or coatings that are difficult to separate during recycling. Instead, opt for water-based or biodegradable inks, adhesives and finishes that align with circular economy goals.
• Incorporate user-friendly features: Easy-open tabs, tear strips or resealable closures can improve the customer experience without adding complexity or waste to the design.
• Stay up to date on regulations and trends: Packaging standards and consumer expectations evolve quickly. Stay informed about current regulations, emerging materials and design trends to stay ahead in the market.

By applying these expert strategies, brands can ensure their paper packaging is not only eco-conscious but also functional, attractive and aligned with both business goals and consumer needs.

The future of paper packaging design

As sustainability continues to move from a consumer preference to a business requirement, the future of packaging lies in solutions that are eco-friendly and innovative. Paper packaging is set to play a leading role in this transition, but its evolution depends on continued advancements in materials, design and collaboration.

The future will see stronger, smarter materials, recyclable barrier coatings, and designs aligned with circular economy principles. Brands will also benefit from increased personalisation and integration of digital features like QR codes for recycling guidance and product traceability.

At Swiftpak, we are leading this shift by helping businesses innovate with paper designs that combine performance, sustainability and cost-efficiency. With over 45 years' expertise, we offer tailored support, from concept to delivery, to ensure your packaging is future-ready.

Partner with Swiftpak for smarter paper packaging designs

As the demand for sustainable, high-performing paper packaging continues to grow, now is the time to future-proof your packaging strategy. At Swiftpak, we combine decades of expertise with a forward-thinking approach to help businesses design and implement packaging solutions that are both innovative and environmentally responsible.

Whether you are looking to reduce plastic use, enhance recyclability or create a memorable customer experience, our team is here to support you every step of the way, from initial concept through to delivery.

Partner with Swiftpak and take the next step toward smarter, more sustainable packaging.