Cooper Henderson, director, segment strategy – flexible packaging at Industrial Physics, tells Packaging Scotland why testing matters more than ever
GLOBAL demand for paper-based packaging continues to climb as brands transition away from plastic under tightening sustainability regulations. Fibre-based materials have become the packaging of choice, but the availability of one of the industry’s most essential raw materials, wood pulp, is under strain. Deforestation, climate change and wildfires, have disrupted supply, while rising energy and labour costs add further pressure on production margins.
At the same time, the closure of ageing paper mills in Europe and North America has left fewer facilities producing a greater share of global output. The result is an industry operating at full capacity under increasingly volatile conditions. For manufacturers and converters alike, these combined pressures highlight the growing need for faster, more precise, and more consistent testing to maintain product quality, performance, and compliance.
A sustainable but variable alternative
As part of wider sustainability commitments, many paper and packaging manufacturers are increasing their use of recycled fibre to reduce dependence on virgin pulp. While this shift is essential to meeting environmental targets, it introduces new challenges for quality control.
Recycled material can vary significantly in composition and cleanliness. Contaminants and inconsistencies affect key properties such as opacity, brightness, strength and surface smoothness – all of which influence how packaging performs. Even a small level of variation can lead to issues of compression, vibration, or changes in humidity. The higher the proportion of recycled content, the greater the variability – and the more vital it becomes to test accurately to maintain consistent quality and performance standards.
The importance of testing
For decades, paper and packaging producers have focused testing on strength, surface quality and printability. But as fibre compositions become more variable, testing has moved beyond routine quality assurance to become a strategic safeguard for efficiency, compliance, and brand reputation. Modern testing regimes must accommodate wider fluctuations in fibre content while verifying recyclability and environmental performance.
This is driving greater reliance on automated and inline systems to maintain accuracy at production speeds that leave little room for error. In an environment of mill consolidation and rising output, the cost of a single quality failure – whether wasted material, unplanned downtime, or rejected shipments – has never been higher. Increasingly, manufacturers are turning to predictive maintenance and real-time data analysis to detect deviations early, cut waste, and protect product integrity.
Innovation under pressure
Recent research from Industrial Physics highlights a clear shift in priorities across the paper packaging community. Only 17% of professionals surveyed said their company was taking an innovative approach to packaging, yet more than half said they expected to do so within the next three years – the highest level of planned innovation among all major packaging materials. More than 60% also reported looking to external partners to accelerate that progress.
The findings reflect an industry under pressure but poised for transformation. Many manufacturers are investing in automation and digital testing systems to counter labour shortages, increase consistency and futureproof production capacity. As sustainability goals and customer expectations continue to tighten, accurate measurement and reliable performance data are becoming the foundation for credible innovation – helping mills bring new materials to market with confidence.
Consumer expectations and regulatory demands
Sustainability remains the defining issue in packaging, but recycled or biodegradable materials must also deliver on strength, integrity and safety. At the same time, new regulations and brand-led audits are requiring verifiable evidence of recyclability and environmental performance.To keep pace, manufacturers need a deeper understanding of how material changes affect product behaviour in real-world conditions. Reliable testing delivers that evidence – helping teams make faster, better-informed decisions and ensuring that every gain in sustainability is matched by equal progress in quality and reliability.
Innovation starts with testing
As the packaging sector faces raw material constraints, cost pressures and ambitious sustainability targets, one reality has become clear: testing is no longer just a final quality check.
Every fibre blend, coating, or surface treatment introduces variables that affect performance and recyclability.
The manufacturers who understand and control those variables through consistent, standards-based testing will set the pace for the next generation of paper innovation.
• To learn more about the challenges facing paper packaging professionals, visit: https://industrialphysics.com/campaign/unlock-growth-in-paper-packaging-with-smarter-testing-and-innovation/
