On 7 August 2024, the CII Sectoral Conference on Printing & Packaging, held at Le Meridian Hotel in New Delhi, brought together industry leaders to discuss key topics like sustainability, innovation, and the resilience of supply chains in the face of evolving challenges. The event set the stage for a comprehensive dialogue on how the printing and packaging sector is adapting to new technological advancements while contributing to India’s economic growth.

The conference opened with a focus on recyclable packaging, particularly in the context of flexible packaging. The panelists were invited to share their perspectives on the current state of recyclable materials, the challenges involved, and the progress made towards developing more sustainable substrates and laminates.

Nestlé’s commitment to sustainability

Ankit Singhai, head procurement – packaging materials, Nestle India, highlighted the company’s ambition to reduce greenhouse gas (GHG) emissions across its entire value chain, from farm to fork. He highlighted that while only 8% of Nestlé’s total emissions stem from packaging, the company remains committed to reducing this footprint. Singhai shared that since 2018, Nestlé has successfully reduced nearly 2,500 metric tons of plastic, though he acknowledged that much work remains to be done.

In terms of material strategy, Singhai explained that Nestlé is focused on designing packaging for recycling. The company is transitioning from multi-material packaging (MMP) to mono-material solutions, which are easier to recycle. This transition is guided by a strategic roadmap with clear targets, and substantial progress has already been made, thanks to collaboration with industry colleagues and business partners.

Challenges in transitioning to sustainable materials

One of the key challenges Singhai highlighted is the cost associated with transitioning to more sustainable materials. He pointed out that much of this cost is absorbed by Nestlé rather than being passed on to consumers. For instance, he noted that the company cannot simply increase the price of products like Maggi noodles to offset the costs of pursuing sustainability. Singhai emphasized the need for the industry to collectively find efficiencies and achieve scale to ensure that sustainability and business can coexist harmoniously.

Huhtamaki’s perspective on industry trends

Ruturaj Kamthekar, vice president of strategic business development, marketing, and product sustainability, Huhtamaki, added to the discussion by acknowledging Nestlé’s role in setting clear guidelines for recyclable packaging, which have been widely adopted by converters like Huhtamaki. Kamthekar noted that the industry is moving away from multi-material, non-recyclable packaging toward mono-material solutions. These mono-material laminates are easier to recycle, whether through mechanical or chemical processes, which is essential for advancing sustainability.

Kamthekar emphasized that while transitioning to new materials presents challenges, such as the need for minimal modifications to existing packaging lines, collaboration between packaging companies and brands like Nestlé is crucial. He highlighted the importance of designing materials that can run efficiently on customers’ lines with only minor adjustments, such as modifications to seal jaws.

Call for industry guidelines

Kamthekar stressed the need for more comprehensive guidelines or requirements for recyclability in India. While there is a guideline for the inclusion of post-consumer recycled material, which will become mandatory by 2025, there is a need for more support for mono-material solutions to facilitate mechanical or chemical recycling. A more holistic approach to sustainability in packaging is essential for the industry’s future.

Supplier perspectives on recyclability and carbon footprint

Nilesh Pinto, zone director, Bobst India, addressed the challenges and progress in making packaging more recyclable and reducing the industry’s carbon footprint. Pinto shared Bobst’s unique position in offering end-to-end solutions that enable close collaboration with many major brand owners. He highlighted the company’s development of mono family laminates, which can replace traditional foil-based and multi family laminates while meeting high barrier requirements and meeting the requirements as per CE regulations. He also highlighted the increasing importance of paper as a substitute for plastic packaging, especially with its excellent barrier properties.

However, the adoption of these advanced materials in India is still limited due to technological constraints and cost challenges. Pinto noted that many setups in India with basic gravure presses struggle to process BOPP due to issues with tension, temperature and registration. This is why BOPET is preferred by printers, given its excellent runnability, mechanical properties, barrier qualities and temperature stability. However, the demand for more advanced materials like MDO, BOPE and high barrier BOPP will grow in the future as the products become more affordable, driven by demand, sustainability and then economies of scale.

The Indian market for gravure machines, for instance, sees around 80 to 100 new machines each year, indicating a maturing market with increasing demands for high-quality films, precise registration tolerances, varied ink types, efficient solvent recovery and skilled labor.

Pinto noted that the Indian laminate market is highly price driven and change will come mainly from governments policies or entrepreneurs’ instincts to differentiate or improve margins.

The role of paperization and transitioning to sustainable practices

The conference also delved into the topic of Paperization, with a focus on the transition from traditional films to more sustainable packaging materials. Prashant Atre, managing director, Toyo Ink Arets India, discussed the critical need for the industry to adapt to recyclable packaging and the key changes required, especially in terms of raw materials. He pointed out that while major players are making progress, many smaller companies are struggling to adopt sustainable practices due to cost pressures. Atre emphasized the importance of collective efforts, particularly in waste collection and recycling, where significant challenges remain.

Water-based inks and the future of printing

Water-based inks were identified as a promising area for the Indian market, with Atre and Pinto both advocating for a shift towards this more sustainable option. Atre noted that while water-based inks still contain some solvents, they represent a significant reduction in solvent use compared to traditional inks, making them a more environmentally friendly option. He also mentioned that some converters in India have already begun adopting water-based systems, but widespread adoption has been slow due to challenges like drying or curing.

Atre also highlighted the strides made in the ink industry, with a shift towards more sustainable products, such as removing harmful substances from packaging inks. He noted that while the transition to water-based chemistry and LED curing is gaining traction globally, the Indian market is still in the early stages of adopting these technologies. He suggested that with proper leadership and collective cost-sharing, sustainability could become more accessible across the industry.

Pinto pointed out that in other markets, particularly in East Asia, the transition to water-based systems has been more rapid, driven by strict environmental regulations. However, in India, the market is still catching up, and more efforts are needed to promote the benefits and feasibility of water-based inks.