Your Essential Guide to Packaging Materials in 2025: What to Use and Why It Matters
Author | Updated Date: 11/7/2025
Table of Contents
What Are Packaging Materials—and Why Do They Matter?
Packaging materials are the structural foundation of every box, sleeve, wrap, or mailer. They’re not just protective shells—they’re brand ambassadors, cost controllers, and silent sustainability advocates.
In 2025, businesses aren’t just choosing packaging materials based on price. They’re choosing based on recyclability, feel, weight, shipping performance, and design compatibility.
Packaging Material Types (2025 Edition)
1. Paperboard (Folding Carton)
A favourite in retail for its versatility and smooth print surface.
What it is: A lightweight, single-ply board often made from virgin or recycled paper fibres.
Why it’s used: It folds easily, accepts high-quality printing (ideal for branding), and is cost-effective at scale.
Common use cases:
- Cereal boxes
- Soap cartons
- Cosmetics sleeves
Environmental status: Often FSC®-certified and 100% recyclable, depending on coatings used. Avoid plastic lamination to keep it eco-friendly.
2. Corrugated Cardboard (Corrugated Fibreboard)
The backbone of e-commerce and bulk packaging.
What it is: Made of fluted paper sandwiched between two flat liners — single wall, double wall, or triple wall depending on strength needed.
Why it’s used: It’s crush-resistant, lightweight, and easy to customise (die-cut, printed, scored).
Common use cases:
- Shipping boxes
- Subscription mailers
- Protective outer cartons
Environmental status: Fully recyclable, often made with high post-consumer recycled content. Widely accepted in kerbside recycling across the UK.
3. Kraft Paper & Kraft Card
Durable, natural, and eco-forward— ideal for brands with an earthy or artisan identity.
What it is: Made from unbleached pulp, kraft paper and kraft card retain their brown tone and strength.
Why it’s used: High tear-resistance, natural look, and suitable for direct food contact (if uncoated).
Common use cases:
- Kraft mailing bags
- Bakery wraps
- Candle or soap sleeves
- Corrugated liners
Environmental status: Biodegradable, compostable, and recyclable. Kraft card is also available in custom thicknesses for more rigid applications.
4. Rigid Board (Greyboard / Chipboard)
Used in premium boxes where structure and unboxing feel matter.
What it is: A dense board made from recycled paper, pressed under pressure for stiffness.
Why it’s used: Gives products a “luxury” presence and resists bending. Can be wrapped in art paper or printed liners.
Common use cases:
Environmental status: Often made from recycled pulp, widely recyclable in its plain form.
5. SBS – Solid Bleached Sulphate (Bleach Card)
A high-grade, premium white card ideal for clean, crisp branding.
What it is: Bleached virgin fibre board with excellent smoothness and strength.
Why it’s used: Excellent for high-end printed packaging, embossing, foiling, and coatings.
Common use cases:
- Pharmaceutical boxes
- Luxury cosmetic cartons
- Food-grade packaging (ice cream tubs, chocolate boxes)
Environmental status: Often FSC®-certified and recyclable, but lamination can limit recyclability.
6. Bux Board (Uncoated Chipboard)
Rough, tough, and industrial-looking — ideal for strong yet affordable packaging.
What it is: A greyish-brown, rigid uncoated board made from recycled material.
Why it’s used: Toughness at a low cost; used for protective applications and bulk outer layers.
Common use cases:
- Heavy-duty box bases
- Outer sleeves for fragile items
- Insert trays
Environmental status: Highly recyclable and made from post-consumer materials.
7. Black Card / Black Kraft
Stylish and dramatic for high-end branding.
What it is: Pulp-based or dyed kraft card in a rich black tone.
Why it’s used: Luxury appeal with excellent contrast for foil stamping or UV spot gloss.
Common use cases:
- Tech accessory boxes
- Premium business card holders
- Subscription kits
Environmental status: Fully recyclable when uncoated or minimally treated. Opt for soy-based inks for better sustainability.
8. Plastic (PET, HDPE, PP)
Still widely used where barrier protection, clarity, or food safety is essential.
What it is: Derived from petroleum, these polymers vary in rigidity, clarity, and barrier properties.
Why it’s used: Moisture resistance, see-through visibility, high sealing performance.
Common use cases:
- Clamshell packaging
- Blister packs
- Bottle closures
Environmental status:
- PET: Recyclable in UK
- HDPE/PP: Recyclable, but depends on local council capabilities
- Avoid PVC or mixed plastics for better eco performance.
9. Glass
A timeless choice for purity and protection.
What it is: Molten sand and minerals hardened into transparent, non-reactive containers.
Why it’s used: Preserves product freshness, perceived as luxurious and safe.
Common use cases:
- Skincare jars
- Candle holders
- Spirits or oils
Environmental status: Infinitely recyclable, though heavy and energy-intensive to produce.
10. Metal (Aluminium or Tin)
Resealable, reusable, and premium in feel.
What it is: Lightweight metal shaped into tins, trays, or screw-top containers.
Why it’s used: Tamper-evident, UV-resistant, and food-safe with a long shelf life.
Common use cases:
- Loose tea tins
- Lip balm or beard balm jars
- Gift sets
Environmental status: 100% recyclable, often with high scrap value — making it one of the most recovered materials.
11. Foam (EPS, EPE, PU)
Protects better than most, but with sustainability trade-offs.
What it is: Expanded plastic foam formed into cushions or corner protectors.
Why it’s used: Lightweight and absorbs impact well — good for fragile items.
Common use cases:
- Electronics packaging
- Glassware shipping
- Medical devices
Environmental status: Usually not recyclable in most UK curbside programmes. Switch to paper-based foam alternatives if possible.
12. Bioplastics & Compostables (PLA, Bagasse, etc.)
Plant-based alternatives for single-use and short lifecycle packaging.
What it is: Derived from corn starch, sugarcane, or mushroom mycelium.
Why it’s used: Eco-conscious brands favour it for being compostable and renewable.
Common use cases:
- Food packaging
- Mailer bags
- Inner trays or void fills
Environmental status: Compostable — but note many require industrial composting. Always label clearly.
13. Pulp Moulded Inserts (Moulded Fibre Trays)
Recycled, strong, and shaped exactly to your product.
What it is: Made from blended recycled paper slurry and formed into moulds.
Why it’s used: Eco-friendly alternative to plastic trays. Offers cushioning, shape retention, and branding potential.
Common use cases:
- Candle jar holders
- Tech product trays
- Gift box inserts
Environmental status: Compostable, recyclable, and biodegradable. Often made with FSC®-certified pulp.
Packaging Material by Function
Function | Suggested Material |
Premium Unboxing | Rigid Board, Black Card, SBS |
Shipping & Transit | Corrugated Cardboard, Pulp Inserts |
Lightweight Retail | Kraft Card, Paperboard, SBS |
Food & Beverage | PET, Glass, Aluminium, Kraft Paper |
Eco Brands | Bux Board, Kraft Card, Pulp, Bioplastics |
Fragile Products | Foam (or Pulp Alternatives), Rigid Board |
Which Packaging Material is Most Sustainable?
In 2025, sustainability isn’t optional—it’s expected. Customers, regulators, and retailers demand eco-conscious choices.
Top Sustainable Picks:
- Kraft Card – natural, recyclable, and biodegradable
- Corrugated Board – efficient and widely recyclable
- Moulded Pulp – a smart alternative to plastic inserts
- Bioplastics – great for food packaging (check compostability standards)
What Are the 4 Levels of Packaging?
- Primary – Direct contact (e.g. a cream jar)
- Secondary – Retail-facing box (e.g. sleeve or carton)
- Tertiary – Shipping (e.g. outer corrugated carton)
- Quaternary – Bulk logistics (e.g. pallet wrap or crate)
Understanding each level helps you choose the right material per layer.
Choosing the Right Material: What to Consider
- Product type: Fragile, food, luxury?
- Transit route: Domestic, international, stacked?
- Sustainability goals: Recyclable? Compostable? FSC®-certified?
- Customer experience: Premium unboxing or minimal cost?
- Print and design needs: Foil stamping? Window cut-outs?
Final Thoughts: Material Choice is Strategy
Choosing packaging material isn’t just a production decision—it’s a branding and sustainability move. The right material can:
- Reduce damage rates
- Lower shipping costs
- Improve perceived value
- Align with eco-conscious consumers
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