Why Choose Cardboard Packaging? Here Are The Benefits for Businesses

Why are more businesses choosing cardboard packaging? Discover its benefits, from reducing plastic and improving recyclability to product protection.

One of the things we're seeing more of at Kingston Carton is customers coming to us with packaging they've used for years, wanting to know if there's a better way of doing things.

For some, it's about reducing plastic, whereas others are looking at sustainability more generally, particularly where materials come from and what happens to the packaging once it's been used.

Cardboard can often offer a good alternative, although it very much depends on the product. We've worked on some interesting projects where we've been able to make a considerable reduction in plastic, while still giving the customer the protection they need.

However, plastic still has its place in the market. There are good reasons why it's used, especially in food packaging where certain barriers are needed to keep products safe and fresh. But we can explore where the use of plastic can be significantly reduced and cardboard can provide a complementary packaging choice.  

What Are the Benefits of Cardboard Packaging?

Sustainability is often what starts the conversation, but there are other reasons why cardboard works so well for manufacturers.

The material is relatively lightweight, which is helpful when you're producing and transporting large quantities of packaging, but it also has the rigidity needed for many different products.

We can produce cartons in all sorts of shapes and sizes, depending on what the customer needs. Some customers have a very clear idea of the packaging they want, while others will come to us with a product and ask our design team to develop something suitable.

There's quite a lot to consider, especially if the cartons are going onto an automated packing line. We have to make sure the board is strong enough, that the folds and creases are in the right places and that the finished design works properly with the customer's machinery.

And if something isn't quite right, it can cause problems further down the production line, so this is an important part of our work.

Cartons can also be supplied flat, which makes them easier to store before they're used, and the fact that cardboard is so adaptable means we can often look at ways of reducing the amount of material required.

Then there's the appearance of the finished carton. We can achieve excellent print quality on cardboard, and customers have plenty of options when it comes to artwork, colour and different finishes.

For products going into supermarkets or other retail environments, this can be particularly useful. A well-designed carton can help a product stand out on the shelf, and it's something we've explored in more detail in our previous blog; how cartons can improve shelf appeal.

Can Cardboard Really Replace Plastic Packaging?

To us, this isn’t about replacing plastic, as plastic still has a place in packaging. But we've had several customers approach us about this, including a venison producer who was using plastic packaging for their meat products.

They wanted to make the packaging more sustainable, but we couldn't compromise on food safety. We looked at the original pack and came up with a design that kept the meat securely wrapped in plastic, with cardboard replacing much of the outer packaging.

We managed to reduce a significant amount of plastic; the product was still just as safe and secure, and arguably it looked better on the shelf as well.

A similar project involved a manufacturer of gumshields. These were originally packaged in plastic containers, and the customer wanted to see if we could develop something using more sustainable materials.

Our team came up with a cardboard design that replaced the rigid plastic outer packaging, with a much smaller amount of shrink wrap protecting the gumshield itself.

Again, there was a considerable reduction in plastic. The product was still secure, and the customer had a carton they could print their branding and product information onto.

We enjoy these sorts of projects because there isn't always an obvious solution until you've looked properly at the product and how it's currently being packaged.

Sometimes a customer might assume they need to change everything, when actually just keeping a small amount of plastic and replacing the rest with cardboard makes more sense.

We're seeing more examples of this across the industry as well. Toothbrushes are increasingly being sold in cardboard packaging, and some of the larger confectionery brands have started changing their packaging formats, too.

We've also worked on cardboard packaging for doughnuts, where changes to the design have helped customers reduce their costs without compromising the finished product. It's another example of how much can be achieved by looking at the packaging more closely.

Why is Cardboard Recycling So Important?

Cardboard is particularly useful for consumer-facing products, as most conventional cardboard packaging can go straight into household recycling. There are some exceptions though, particularly where cardboard contains plastic or foil linings, certain coatings or heavy food contamination, but generally it's a straightforward material for people to recycle at home.

Some plastic packaging is also widely recyclable, but certain films and other materials need to be taken to supermarket collection points or handled through different recycling systems.

With cardboard, we already have a well-established recycling process in place.

Another interesting point is how often the fibres can be recycled. Traditionally, the industry has talked about paper and board fibres being recycled around seven times before they eventually become too short or weak to use again. 

However, research suggests they can last much longer than that. A 2021 study by Graz University of Technology, published by Pro Carton, found that cardboard could go through at least 25 recycling cycles without any significant loss of strength under test conditions. That's encouraging, particularly when you consider how many times those fibres could potentially be used to make new packaging.

Cardboard is also made from natural wood fibres, so certain types are biodegradable and can be composted under the right conditions.

However, we would always encourage people to recycle suitable cardboard rather than compost it. We want those fibres to be collected and used again, which is much more beneficial than losing them from the recycling process.

There are still things we have to be careful of though, particularly where food packaging needs a plastic barrier or a specialist coating. These can affect how easily a carton can be recycled, which is why we spend time helping customers select the right materials in the first place.

Is Virgin Cardboard Less Sustainable Than Recycled Board?

There's an assumption that recycled cardboard must always be better for the environment, but that isn't necessarily the case.

Virgin cardboard is produced using new wood fibres, whereas recycled board has already been through the recycling process. Both can be recycled again, and there are different reasons why we might recommend one over the other.

For example, virgin cardboard is often preferred for certain food-contact applications, where the purity of the material and the risk of contamination are particularly important.

Recycled board can also be used for food packaging where it meets the necessary requirements, but we need to understand what the product is and how the packaging will be used before deciding.

The other point that’s worth explaining is how virgin cardboard is made, because people sometimes hear or see the word 'virgin' and assume it must involve cutting down trees without replacing them.

The board we source comes from responsibly managed sources, much of it from Europe, where forestry is managed to provide a continuing supply of wood.

Trees are grown and harvested, with new planting and natural regeneration allowing the forest resource to be maintained. It's a managed process, and that's something customers are increasingly interested in understanding.

At Kingston Carton, we hold FSC and PEFC chain-of-custody certifications, and if customers want to use the relevant logos on their packaging, we can help them source suitable certified materials and make sure the correct requirements are followed.

We regularly talk customers through these differences because the right choice isn't always as obvious as simply asking for recycled board.

Do Businesses Know Where Their Cardboard Comes From?

Some do, although we're certainly getting more questions about it than we used to.

We've completed more carbon footprint surveys in recent years than ever before, with customers asking about everything from the electricity used during manufacturing to where our cardboard comes from and how it's produced.

A lot of this comes down to businesses wanting a better understanding of their supply chains. For those reporting on their environmental performance, particularly larger organisations, the information we can provide about our materials and suppliers can be useful.

One of the things we can do is arrange for customers to visit a paper mill in the Lake District, where they can see how the material is manufactured. We think this is a great experience because there's a lot involved in producing paper and board that might not otherwise spring to mind.

Water, for example, is a major part of papermaking, so the way mills manage and treat it is extremely important. Energy use is another area where manufacturers are making improvements, with some mills increasingly turning to fossil-free electricity and more efficient production processes.

It's useful for customers to see the scale of the operation and understand what goes into making the board before it even reaches us in Hull.

We can talk people through the information they need, but sometimes seeing the process for yourself explains things much better.

And with more customers having to account for their own carbon footprint and the materials they purchase, this sort of knowledge is becoming more valuable.

What Packaging Changes Are Coming in 2027?

Another reason we're having more conversations about recyclable packaging is the amount of legislation businesses now need to be aware of.

The UK's Extended Producer Responsibility scheme is already changing how qualifying businesses account for the packaging they place on the market.

One of the important developments for 2027 is the updated Recyclability Assessment Methodology, known as RAM 2027.

This assesses how recyclable different packaging materials are through the UK's collection and recycling systems, with packaging given a red, amber or green rating.

For businesses covered by the requirements, those ratings are important because they influence packaging waste disposal fees.

Cardboard is generally well suited to the recycling infrastructure we have in the UK, although we still need to consider the complete packaging design.

For example, under the 2027 methodology, paper and board packaging with more than 5% plastic content by weight is assessed as a fibre-based composite rather than under the usual paper and board category.

Now, that doesn’t mean everything below 5% automatically receives a green rating, as other features of the packaging can affect recyclability.

It’s the sort of detail that customers need to understand, particularly if their cartons require grease-resistant barriers or other additional materials.

We can help them look at the specification and understand what might need changing, along with providing information about environmental claims and the certification logos they’re entitled to use.

There are also changes relating to responsible sourcing, including the EU Deforestation Regulation, which will introduce traceability and due diligence requirements on certain products and businesses operating within relevant EU supply chains.

With so much to consider, we’re finding customers appreciate being able to speak to a packaging manufacturer who understands the materials and can help them work through the practical implications.

Could Your Business Be Using More Cardboard?

It’s encouraging that more businesses are prepared to question packaging they've used for a long time.

Sometimes a customer will come to us specifically wanting to reduce plastic, but they might not know how much can realistically be replaced or what effect it could have on the finished product.

That's where we can help.

We manufacture more than 350 million cartons every year at Kingston Carton, and our team has experience working with all sorts of products and packaging requirements.

If a customer is considering switching to cardboard, we'll look at what they're currently using, what the packaging needs to do and whether there's a better solution available.

The venison and gumshield examples show the sort of changes that can be made, and we expect to see more customers exploring similar ideas as sustainability and recyclability continue to influence packaging decisions.

Want to Know More? 

At Kingston Carton, we've been manufacturing carton packaging for more than a century for customers across the UK. Contact us for more information or get in touch using the email and number below.

Whether it’s packaging for food, healthcare or horticulture, our sustainable packaging can be a great choice for your business.

We know how to create quality packaging that stands out on the shelf.