This article first appeared in the August 2025 issue of ProPack.pro

As packaging continues to evolve, sustainability, efficiency, and customer experience are at
the forefront of this year’s trends. Businesses are seeking recyclable materials, durable packaging designs, and engaging unboxing experiences. 

The need for more recycled content in cardboard packaging

National Packaging Targets, company sustainability goals, and an increase in consumer interest are driving the demand for more recycled content in packaging. 

Opal’s partnership with John Dee, a leading Australian meat processor, demonstrates how recycled paper and recyclability can be integrated into high-performance packaging: 

• John Dee’s chilled meat boxes now contain 73 per cent recycled content, up from 48 per cent
• The recyclable bases of frozen meat boxes have increased from 35 per cent to 66 per cent
• The recyclable lids of frozen meat boxes have risen from 37 per cent
  to 69 per cent

By leveraging its Dura-Flute Mediums and Premium Recycled Liner, Opal developed a solution that maintains strength and durability, even in high-humidity conditions. This ensures John Dee meets its sustainability goals without compromising on performance. 

Bringing the ‘wow factor’ to every unboxing experience

Packaging is no longer just about protection – it offers the opportunity to bring a brand’s personality to life and create an impactful unboxing experience for consumers. 

Brands are looking to create packaging that is functional, visually engaging, and features unique design elements including:

• Thoughtful structural design that ensures packaging is easy to open while protecting the product inside
• High-quality printing and die-cutting that showcases colour and adds tactile depth to packaging, delivering a premium feel
• Using materials that are recycled and recyclable, with certifications that demonstrate cardboard products are manufactured with responsibly sourced wood fibre.

Minimalist yet high impact – streamlining e-Commerce packaging

The rise of e-Commerce is driving demand for packaging that is simple to assemble with minimal assembling steps, strong enough for transit, and efficient for logistics operations. 

Brands are prioritising solutions that are:

• Easy-to-assemble while reducing the number of steps in the fulfilment process
• Made of strong and durable materials that protect products during shipping
• Optimised shipper designs that reduce excess materials, help improve sustainability and increases cost-effectiveness within the packaging supply chain

Opal is developing easy-fold mailers and robust shipper solutions that support cost-effective fulfilment while reducing material use. By integrating recyclable materials into packaging solutions, Opal supports businesses with their sustainability targets.

When the co-founders of Bronte Body came to Opal, their brief was, “make it beautiful, make it recyclable”. 

Collaborating with Bronte Body, Opal developed e-Commerce mailers that wove elements of luxury and minimalist design. 

Delivering cardboard alternatives to expanded polystyrene

Consumers are driving changes in the packaging industry by moving away from plastics. Fresh food producers and FMCG brands that rely on cold storage are now expected to provide packaging that includes recycled materials and can be recycled when it can no longer be used.

This presents a challenge for fresh food producers who rely on the thermal capabilities of Expanded Polystyrene (EPS) to keep their produce fresher for longer. For example, EPS is a common solution, but it is difficult to recycle within kerbside recycling systems.

Opal solved this problem for Petuna Seafoods by developing a corrugated cardboard alternative to its whole fish packaging solution. The design features moisture barrier properties that withstand low temperatures for fresh chilled products, and a functional coating allowing imagery to be laid down onto kraft paper.

From increasing the use of recycled materials to optimising packaging for e-Commerce, Opal’s commitment to sustainability, performance, and design ensures businesses can continue to
meet evolving consumer demands. 

This is an excerpt from Opal’s blog.