How Raw & Expandable Materials Are Driving Sustainable Packaging Innovation

Rising transport costs, tighter waste reporting requirements, and constant pressure to reduce pack weight are forcing teams to rethink what “good” means for flexible packaging materials. Data reports annual plastic production climbed from 2 million tonnes in 1950 to around 460 million tonnes by 2019, sharpening the focus on material efficiency alongside reliability. One response gaining traction is the use of raw, expandable materials. These formats are shipped compact and then activated near pack-out to provide protection with less volume and material. Options range from inflatable cushioning and foam-in-place to line-converted paper systems, where activation must match line speed and quality control.



Why Expandability Changes The Logistics Maths


Expandable formats can shift costs to areas that finance teams actually track. By moving less air, sites can improve pallet density and reduce pressure on the warehouse footprint. Packaging teams also gain a bit more freedom to right-size protection, particularly when product mixes change and stock-keeping units (SKUs) proliferate.



There is a useful parallel here with right-sizing principles in e-commerce packaging. EcoEnclose notes that reducing pack dimensions can lower both material purchases and shipping costs when carriers price by dimensional weight. While that example is not limited to expandables, it reflects the same underlying dynamic: volume has a price.

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