Sustainable materials revolutionising tertiary packaging choices

As supply chains come under increasing pressure to reduce waste and emissions, materials such as high-recycled-content corrugated board, fibre-based solutions and bio-derived alternatives are moving from niche to mainstream. This shift is being accelerated by tighter regulations such as Extended Producer Responsibility (EPR), growing customer expectations for sustainable logistics, and the need for more efficient, space-optimised palletisation.

For businesses, tertiary packaging is no longer just about protection in transit, it’s a strategic opportunity to cut carbon, improve operational efficiency and strengthen environmental credentials. While primary packaging at the primary level focuses on individual products, the difference with tertiary packaging lies in its main purpose, protecting goods at scale during storage and transport. Sustainable materials now deliver the durability, load stability and double-pallet compatibility required by modern logistics, while supporting circular economy goals.

In this blog, we explore how these materials are transforming tertiary packaging choices, the benefits they bring across the supply chain, and how Swiftpak is helping organisations transition to more sustainable, future-ready solutions.

What are sustainable materials for tertiary packaging?

Sustainable materials for tertiary packaging are designed to protect goods during bulk handling, storage and transport while reducing environmental impact. When assessing the different types of sustainable tertiary materials available, several key factors, such as strength, weight, recyclability and cost, determine the most suitable packaging solution.

Unlike traditional plastic stretch films, foams and void fillers, these alternatives prioritise recyclability, renewable inputs and circular use, without compromising on performance or logistics efficiency.

Key options include:

• High-PCR corrugated cardboard: Manufactured with a high percentage of recycled fibre, it offers excellent compression strength and load stability for palletised goods. It is commonly used to produce robust cardboard boxes, shipping boxes, pallet collars and layer pads. These boxes support secure stacking and compatibility with double pallet utilisation across distribution networks.
• Bio-based films: These are another emerging solution, produced from renewable resources such as plant starches or cellulose. These films can be used for pallet wrapping or load containment, delivering comparable stretch, tear resistance and transparency to conventional plastic films while reducing reliance on fossil fuels.
• Mycelium foams: These are grown from fungal networks and agricultural by-products. They provide a natural alternative to expanded plastic foams. They offer excellent shock absorption and cushioning for heavy or fragile goods, ensuring each piece of packaging protects loads during transit while being fully compostable at end of life.
• Fibre-based paperisation solutions: These replace plastic components with reinforced paper and moulded fibre formats. These materials can be engineered to deliver high-load bearing capacity, abrasion resistance and dimensional stability, enabling effective pallet protection and secure handling. Their lightweight nature also supports efficient double pallet utilisation without adding unnecessary mass.

Together, these sustainable materials demonstrate that tertiary packaging can achieve the strength, protection and supply chain compatibility required for modern logistics, while significantly reducing environmental impact and maintaining product integrity to a high standard.

Sustainability advantages

Switching to sustainable materials for tertiary packaging delivers more than regulatory compliance, it enables genuine environmental improvement across the supply chain. Designed with end-of-life considerations in mind, these materials help businesses reduce waste, cut emissions and support circular economy principles.

Key sustainability benefits include:

• Recyclability and compostability: Fibre-based solutions and high-PCR corrugated materials are widely recyclable through existing waste streams, while innovative materials such as mycelium foams are fully compostable. This ensures packaging can be recovered or naturally broken down, rather than sent to landfill.
• Reduced reliance on fossil fuels: By increasing the use of recycled content and bio-based raw materials, sustainable tertiary packaging limits the need for virgin plastics and finite resources. This supports a shift towards renewable inputs and more responsible material sourcing.

In addition to material choice, sustainable tertiary packaging also delivers measurable environmental performance gains:

• Lower carbon footprints: Recycled and bio-derived materials generally require less energy to manufacture. Combined with lightweight designs and efficient pallet utilisation, they can help reduce transport emissions and overall carbon impact.
• Landfill diversion: Recyclable and compostable packaging options significantly reduce the volume of waste sent to landfill, supporting waste reduction targets and improving environmental reporting.

These advantages make sustainable tertiary packaging a practical way for businesses to reduce environmental impact while maintaining the strength, protection and efficiency required for modern logistics.

Practical benefits for businesses

Sustainable tertiary packaging offers tangible commercial advantages alongside environmental gains. Modern fibre-based and recycled materials are engineered for strength and consistency, enabling better pallet stability, smoother handling within the warehouse and across transport networks, including shipping containers.

Cost savings are another key driver. High-PCR and recycled-content materials help businesses meet regulatory requirements while reducing exposure to EPR fees and virgin plastic price volatility. Recyclable designs also minimise waste and disposal costs, and scalable production ensures reliable supply at competitive pricing.

Crucially, these solutions are highly versatile. From industrial and manufacturing sectors to retail packaging, ecommerce, food and pharmaceuticals, sustainable tertiary packaging delivers the durability, efficiency and adaptability needed to perform across a wide range of industries.

Enhancing supply chain and brand reputation

Sustainable tertiary packaging is increasingly seen as a strategic lever for strengthening both supply chains and brand reputation. Circular designs that replace traditional materials such as plastic crates, plastic pallets and even transport solutions used alongside plastic bottles support improved ESG performance and regulatory compliance.

Adopting circular packaging solutions also sends a clear signal of environmental leadership. Using high-recycled-content and bio-based materials demonstrates a proactive commitment to reducing environmental impact. This can strengthen relationships with customers, retailers and logistics partners who prioritise sustainability.

In competitive markets, this visible commitment helps differentiate brands, enhances trust and supports long-term commercial growth.

Swiftpak’s sustainable tertiary packaging solutions

Swiftpak supports businesses in transitioning to more sustainable tertiary packaging without compromising on performance or protection. Our range includes ready packaging solutions is designed to meet the demands of modern logistics while aligning with circular economy goals and regulatory requirements.

We offer a broad portfolio of fibre-based and high-recycled-content packaging solutions, including pallet protection, load stabilisation and transit packaging engineered for strength and efficiency. Alongside our products, we provide expert packaging advice, working closely with customers to develop tailored solutions that reduce environmental impact while supporting operational efficiency and supply chain resilience.

Sustainable materials for effective tertiary packaging

Sustainable materials are proving that eco-friendly packaging doesn’t mean compromising on performance. By combining strength, protection and compatibility with modern logistics, solutions like high-PCR corrugated cardboard, bio-based films, mycelium foams, and fibre-based paperisation strike a balance between environmental impact, cost-efficiency, and operational effectiveness.

For businesses looking to reduce waste, cut carbon, and optimise their supply chains, adopting these innovations offers tangible benefits, from lower disposal costs and regulatory compliance to improved pallet efficiency and brand reputation.

Swiftpak is ready to help you explore tailored tertiary packaging solutions that meet your unique needs. By embracing sustainable materials today, you can protect your products, your business, and the planet.