Plastic vs Paper Packaging: The Pros and Cons

For example, cardboard production is water intensive, generates emissions and runs the risk of encouraging deforestation if not sourced sustainably. On top of that it is difficult to recycle if contaminated with food or other waste.

So, are paper and cardboard really more eco-friendly than plastic? Could Bioplastics be the answer to all sustainability problems? In this article, we will look at the bigger picture and explore the pros and cons for both plastic and paper.

Packaging choices also have financial and regulatory implications. UK Extended Producer Responsibility (EPR) fees now reflect packaging recyclability, the Plastic Packaging Tax rate has increased, and the EU Packaging and Packaging Waste Regulation (PPWR) began applying in August 2026. We explain what these changes mean for businesses further down in the article.

We know you are busy, so we decided to put in a quick table with the pros and cons of both plastic and paper, so you can see the clear positives and negatives of each that are discussed further in this article.

Plastic

Plastics came into existence by accident in 1907, but it grew popular around the 1950s when high-density polyethylene was created. Plastics are made from fossil fuels which is clearly a non-renewable source. It is estimated that 4% of the world’s oil production is used as feedstock to make plastics, so this means plastic is often viewed as poor material in terms of renewability and sustainability.

However, it's not all doom and gloom with plastic. In recent times various reports from credible sources such as McKinsey have come out that plastic also brings certain benefits compared to other materials such as paper. The most sustainable approach is to look at the bigger picture, compare the pros and cons of the material and see them in the context of what situation the material is used.

The Plastic Pro’s

Although they are bad for the environment, there are a number of reasons why some may find plastics difficult to give up. These are as follows:

• Low costs: Plastic is the cheapest out of all common packaging materials.
• Excellent Durability: Plastics do not break or get damaged easily and can withstand falls or slight trauma without damage so provides great protection. Plastic packaging often does not get damaged when stacked on top of each other, making transportation of products easier.
• Long lasting: Plastic takes about a thousand years to break down, they can last for extensive periods without damage. However, as much as this is a pro, it is also a con.
• Light weight: Most plastic materials weigh almost nothing when compared to alternatives such as glass and wood, which is great in reducing the footprint when transporting products that are packaged with plastics.
• Great versatility: Plastic packaging has many forms that can vary from flexible and adaptable to sturdy and resilient types like plastic containers.
• Low GHG footprint: McKinsey tested plastic and non-plastic alternatives to look at the impact. Among applications for which nonplastic alternatives are used at scale, the plastics examined in their research offered lower total GHG contribution compared with alternatives in approximately 90% of cases. This finding applies to the applications and assumptions in that research; it should not be interpreted as meaning that plastic is always the lower-carbon option

The Plastic Con’s

Plastics may provide a number of easy advantages for businesses as mentioned above, but this does not mean the cons should be disregarded.

Plastic production is around 381 million tons and 5 trillion or more pieces of plastic are polluting the waters around the world. However, more consumers are demanding recycled content in plastic which is driving accelerated progress in recycling plastics. Some additional cons include:

• Dependency on Fossil Fuels: Plastic is primarily derived from fossil fuels, such as petroleum and natural gas. This contributes to carbon emissions and dependence on non-renewable resources.
• Single-use nature: A significant portion of plastic packaging is designed for single-use purposes, leading to excessive waste generation and resource consumption.
• Long lasting: As mentioned in the pro’s, it can take thousands of years to fully degrade, which is harmful to the environment when it does not end up in the recycling scheme.
• Non-biodegradable: Most plastics are not biodegradable, which means they persist in the environment and can accumulate over time, adding to the pollution in seas and other habitats across the world.
• Chemical Leaching: Some types of plastic packaging, especially those made with certain additives, can pose potential health risks when used around food and beverages.

Innovations in plastic recycling

It’s no surprise that plastic waste has become a global concern due to its impact on the environment and human health. However, advancements in plastic recycling technologies offer promising solutions to tackle this issue.

It is important to distinguish between technologies that have the potential to improve recycling and those that are widely available in commercial waste-management systems. The environmental benefits also depend on the process used and the material recovered.

Let’s explore some of these innovations and how they can improve the recyclability of plastic packaging.

Chemical recycling

One notable breakthrough in plastic recycling is chemical recycling. Unlike traditional mechanical recycling, which involves melting and reforming plastic, chemical recycling breaks down plastic into its molecular components. This process allows for the conversion of plastic waste back into its original building blocks, which can then be reused to produce new plastic products. Chemical recycling has the potential to recycle a wider range of plastic types, including mixed or contaminated plastics that would otherwise be challenging to recycle mechanically without separating beforehand.

Advanced sorting systems

Sorting plastic waste effectively is crucial for efficient recycling, especially with plastic packaging. Advanced sorting systems, such as artificial intelligence (AI) and robotic technologies, have revolutionised the recycling industry. These systems can accurately identify and separate different types of plastic based on their composition, colour, and shape. By automating the sorting process, these technologies increase recycling efficiency, minimise human error, and enhance the quality of recycled plastic.

Depolymerisation

Depolymerisation is another innovative technique that breaks down plastic into its monomers or basic chemical units. By using heat or solvents, plastic polymers are disassembled, allowing for the recovery of valuable monomers. These monomers can then be used as raw materials for producing new plastic products without losing their quality. Depolymerisation shows promise in enabling the recycling of plastics that are difficult to recycle through conventional methods.

Bioplastics

If for your company the pro’s outweigh the con’s, then it might be an option to consider bioplastics. Bioplastics are made from biodegradable sources such as vegetables, rice, and other organic and plant-based compounds.

Similar to other plastics, bioplastics are not currently recyclable, but they do break down much quicker than regular plastics, provided they are properly composted at in-home compost heaps or in extensive industrial compost facilities.

Bioplastics are usually much more efficient and eco-friendly than normal plastics and help contribute to the reducing of pollution.

Biobased does not automatically mean biodegradable, and biodegradable does not automatically mean suitable for home composting or conventional plastic recycling. The correct disposal route depends on the specific material and the facilities available.

At Swiftpak, we would recommend trying our polylactic acid (PLA) packaging as it is made from the renewable source, cornstarch, and so decomposes well in the presence of acids. PLA can be used for grocery bags, food packaging, thermal insulation as well as for medical applications.

PLA should not be described as universally recyclable or as something that will readily decompose in a home compost heap. Many PLA products require appropriate industrial composting conditions, and acceptance depends on local facilities. Businesses should check the product specification and disposal instructions before choosing it.

Common misconceptions about plastic and paper packaging

As the demand for sustainable packaging continues to grow, many businesses are under pressure to switch materials quickly, often without fully understanding the environmental trade-offs involved. To help you make better-informed decisions, let’s discuss some of the most common misconceptions about plastic and paper packaging.

1. Paper is always more eco-friendly than plastic: While paper is biodegradable and generally breaks down faster than plastic, its production can be more resource intensive. Creating paper or cardboard packaging requires significantly more water and energy. Without sustainable sourcing or effective recycling systems, paper’s environmental impact can be higher than expected. Paper is not automatically the more sustainable choice for every application. A fair comparison should assess packaging that performs the same function and protects the product to the same standard.
2. All plastics are bad for the environment: It is true that plastics have contributed to significant environmental damage, particularly due to improper disposal and reliance on fossil fuels. However, not all plastics are created equal. When reused or effectively recycled, certain plastics can have a lower carbon footprint over their lifecycle compared to glass, aluminium or even paper. The aim should be to avoid unnecessary plastic, use materials efficiently and select packaging that can be reused or managed responsibly at the end of its useful life.
3. Cardboard packaging can always be recycled: Although cardboard is highly recyclable, it becomes non-recyclable when contaminated with food, grease or liquids. A greasy pizza box, for example, cannot be processed by most recycling facilities. Businesses should check whether their specific packaging format is accepted by the relevant recycling system rather than assuming that all paper-based packaging can be recycled in the same way.

Paper and Cardboard

Paper and cardboard remain popular packaging choices for businesses looking to reduce their reliance on plastic.

Rather than relying on outdated references to Brexit, the pandemic and cardboard shortages, it is more useful to consider the current packaging landscape: recyclability, material costs and changing regulatory requirements.

Paper-based packaging has established recycling routes, and cardboard boxes can often be reused before being recycled. However, the suitability of paper depends on the product, the level of protection required and the packaging's construction.

The UK Plastic Packaging Tax also creates a financial incentive to use recycled plastic in qualifying packaging components. Meanwhile, packaging EPR fees increasingly reflect recyclability, meaning that both paper and plastic packaging design can affect compliance costs.

For businesses exporting to the EU, the PPWR adds another consideration, with new requirements being introduced in stages from August 2026 onwards. These developments make it increasingly important to review packaging materials and their end-of-life options.

The Paper and Cardboard Pro's

So, is paper more sustainable than plastic? The use of cardboard most definitely has its pros over the plastic alternative. Some of these include:

• Recyclable: Cardboard is sourced from renewable wood pulp (processed into kraft paper) or recycled cardboard material. This means it has a high recycling rate of 85.8 in Europe, whereas plastic is mostly sent to landfill.
• Sustainable: Cardboard has a clear sustainability benefit over plastic as it is biodegradable and breaks down much quicker.
• Reusable: One of the greatest advantages is that cardboard boxes can be used again, and with the corners of the boxes being flexible, they can be collapsed when not in use.
• Printing and design: Cardboard can be printed on easily making it perfect for marketing, branding, and promotional purposes.
• Cost savings: Buying cardboard in bulk can save your business good deals of money due to their reusability.
• Extended storage: As long as it is protected from water, cardboard can be stored for long periods of time.

At Swiftpak, we have a range of corrugated cartons that you can use instead of plastic. Corrugated cardboard boxes have many advantages that include being entirely recyclable making them more environmentally friendly than most plastics, whilst also being tear-resistant and highly affordable compared to other alternatives.

The Paper and Cardboard Con’s

Although many companies are making the switch from plastic to paper products such as cardboard, it is important to recognise that cardboard also has its own environmental issues.

• Less durable: Cardboard is much less durable than plastic and can be susceptible to mould, fire, and water damages due to weather.
• Stacking difficulties: Cardboard is not able to hold as much weight as plastic and so cannot be stacked as easily without breakage.
• Moisture damage: Cardboard is not the best for weatherproofing as water and other types of liquid seep into the box and damage the contents inside.
• Recycling rate: Paper cannot be recycled infinitely, it is said it can only be recycled 5-7 times before the fibres become too short.
• Energy used during production: Boustead Consulting & Associates study revealed manufacturing 1,000 paper bags requires 3.4 times more energy than traditional plastic.
• Bigger footprint during transportation: As plastic is lighter and thinner than cardboard alternatives, the logistics footprint of paper-based material is higher.
• Global deforestation: Paper is made from trees, which is a renewable source. However, check if your cardboard or paper is FSC certified as you don’t want to add to global deforestation. At Swiftpak, we make it easy for our customers to re-plant the trees they have used.

Paper Void Fill

Paper void fill is great solution if you are looking to minimise the amount of plastic you use. It is a good alternative to bubble wrap as it is eco-friendly, recyclable, and re-usable. This void fill is also much more affordable and available on the market.

Paper void fill helps to protect your items during transit in a similar way to foam chips by filling up the remaining space, providing products with protective cushioning they need.

As with other packaging materials, the best choice depends on the level of cushioning required. Fragile, moisture-sensitive or unusually shaped items may need a different solution or a combination of protective materials. The priority should be to prevent damage without using more packaging than necessary.

When to use plastic vs paper packaging

There’s no one-size-fits-all solution when it comes to choosing the right packaging material. The decision often depends on the specific needs of your product, environmental goals, industry requirements and logistics considerations. Here is a breakdown of when to use plastic, paper or bioplastic, and which industries benefit most from each material.

When to use plastic packaging

Best suited for industries that require high durability, moisture resistance and long shelf life.

• Food and beverage: Plastic is ideal for products requiring airtight seals or moisture protection.
• Pharmaceuticals and healthcare: Due to hygiene, tamper-proofing and chemical resistance, plastic remains essential in medical packaging.
• Electronics: Static shielding and protective cushioning make plastic perfect for sensitive items.

When to use paper and cardboard packaging

Best suited for industries focusing on sustainability, branding and lower-risk product transport.

• Ecommerce and retail: Corrugated cardboard boxes are excellent for shipping non-fragile items like clothing, books and consumer goods.
• Dry food items: Ideal for dry foods, baked goods or takeaway meals, especially when compostable liners are used.
• Cosmetics and personal care: Kraft paper or custom-printed cardboard elevates branding and reduces plastic use.
• Subscription boxes: Offers a tactile, premium unboxing experience while being fully recyclable.

When to consider bioplastics

Best suited for brands looking to reduce fossil fuel use and offer compostable options.

• Organic or health-focused food brands: PLA trays or wrappers align with sustainability promises.
• Retail and grocery: Compostable carrier bags and produce bags reduce single-use plastic reliance.
• Hospitality and events: Compostable cups, cutlery and containers are increasingly popular at zero-waste venues.

Businesses should not assume that a bioplastic is automatically more sustainable than conventional plastic of paper. Check its composition, performance, certification and actual disposal route before making a decision.

Understanding the UK plastic packaging tax: What it means for your business

The UK Plastic Packaging Tax was introduced in April 2022 to encourage the use of recycled plastic and reduce reliance on virgin material.

From 1 April 2026, the rate is £228.82 per tonne for qualifying finished plastic packaging components containing less than 30% recycled plastic. The tax applies subject to the relevant definitions, exemptions and registration requirements.

Manufacturers and importers generally need to register if they have manufactured or imported 10 tonnes or more of finished plastic packaging components in the previous 12 months, or expect to do so in the next 30 days. Registration and reporting obligations can apply even where all relevant packaging meets the recycled-content threshold.

Why it matters for your business:

1. Cost pressure: Qualifying plastic packaging below the recycled-content threshold can incur a tax charge.
2. Material choices: Businesses may assess recycling plastic, paper or cardboard alternatives where these meet the product’s protection requirements.
3. Recycled-material sourcing: Availability, quality and price can affect whether recycled plastic is suitable for a particular packaging application.
4. Future planning: Understanding the tax alongside Extended Producer Responsibility (EPR) can help businesses assess their packaging costs and obligations.

It is important to distinguish the Plastic Packaging Tax from EPR. The tax focuses on recycled-plastic content in qualifying packaging components. EPR helps fund packaging waste management and increasingly adjusts fees according to recyclability. The two schemes have different rules and may have separate financial implications for a business.

What does EPR mean for paper and plastic packaging?

Extended Producer Responsibility (EPR) came into force in the UK in 2025. It requires obligated businesses to contribute towards the costs of managing packaging waste. From 2026, the scheme introduces recyclability-based fee modulation, with green, amber and red classifications affecting disposal fees for eligible large producers.

Plastic packaging can attract higher fees where it is difficult to recycle. Paper and board can qualify for lower fees when they meet the relevant recyclability criteria, but paper packaging is not automatically exempt from

EPR or guaranteed the lowest rate. Coatings, laminates, contamination and mixed materials can affect classification.

Businesses should review their packaging specifications, confirm their reporting obligations and check the applicable fee schedule when assessing potential costs.

EU PPWR: What UK exporters need to know

The EU Packaging and Packaging Waste Regulation (PPWR), Regulation (EU) 2025/40, began applying on 12 August 2026. It introduces a common framework for packaging across the EU, with requirements covering recyclability, packaging waste reduction, recycled content, labelling and certain substances used in packaging.

For UK businesses exporting products to EU customers, the regulation adds another layer to packaging compliance. Meeting UK requirements does not automatically establish compliance with every applicable EU rule.

Key developments include:

• Recyclability: Requirements intended to make all packaging recyclable apply from 2030, subject to the regulation's detailed provisions.
• Recycled plastic content: Mandatory recycled-content requirements for specified plastic packaging apply from 2030, with targets depending on the packaging category.
• Packaging reduction: Measures addressing unnecessary packaging and excess empty space in deliveries apply from 2030.
• Labelling: Harmonised EU packaging labelling requirements are being introduced, with key measures scheduled from 2028.
• Food-contact packaging: Restrictions on PFAS in food-contact packaging began applying on 12 August 2026, subject to the regulation's limits and provisions.

What should exporters do?

Businesses selling into the EU should:

• Review packaging materials, coatings, adhesives and recycled content.
• Check the recyclability of the complete packaging format.
• Review food-contact requirements where relevant.
• Confirm which business is responsible for applicable producer registration, reporting and compliance in each destination market.
• Plan for phased deadlines rather than assuming every requirement applied in August 2026.

PPWR does not mean that all plastic packaging is banned or that paper packaging is automatically compliant. Businesses should check the rules relevant to their products, packaging formats and destination markets.

Cardboard vs Plastic from Swiftpak

At the end of the day, the right choice depends on what you are shipping and the protection it requires.

Cardboard boxes can be a cost-effective option because they can be reused and are widely recyclable when suitable for local collection systems. However, stacking limitations and moisture sensitivity need to be considered, particularly where boxes will carry heavy loads or be exposed to damp conditions.

Plastic can provide advantages in applications where flexibility, moisture resistance or specialist protection is important. Recycled plastic may also be suitable for some applications, depending on the material specification and intended use.

A switch to bioplastic should not be treated as a universal solution. Bioplastics vary in their properties and disposal requirements, so businesses should check whether the product is suitable for their application and whether appropriate recycling or composting facilities are available.

There is no one-size-fits-all answer. Businesses should assess the packaging they use individually, considering product protection, material efficiency, environmental impact and applicable regulatory costs.

At Swiftpak, we can help you assess your packaging requirements and explore suitable paper and plastic solutions for your business.

Contact our packaging experts today for more information on cardboard and plastic packaging and to discuss which option is best for your products and operations.