Sustainable Packaging Middle East & Africa Magazine - Issue 7
The real cost of packaging innovation
Innovation drives progress, but it rarely comes cheap, especially in the world of packaging. Today’s manufacturers find themselves in a difficult position: consumers and regulators demand smarter, more sustainable solutions, yet implementing these innovations can be expensive and complex. While the industry recognizes the urgent need for change, the reality is that the financial burden of innovation can be daunting.
One of the biggest challenges is the shift toward sustainable materials. The movement to reduce plastic waste has gained momentum, but transitioning to biodegradable, compostable, or plant-based alternatives is far from straightforward.
These materials often require specialized production methods, making them more expensive and less accessible than traditional plastics. A bio-based plastic bottle, for instance, can cost up to 50% more than a standard PET one. For largescale manufacturers, that price difference quickly adds up, impacting profitability.
Beyond material costs, regulatory compliance is another factor increasing expenses. Governments worldwide are tightening packaging laws, banning single-use plastics, and enforcing recyclability requirements.
For manufacturers, meeting these new standards means redesigning packaging, investing in updated machinery, and securing necessary certifications. The financial impact is even greater for companies that export to multiple countries, as they must navigate varying regulations, each with its own compliance costs.
Then comes the rise of smart packaging, technologies like QR codes, freshness indicators, and RFID tracking. These
However, integrating them requires high initial investment, ongoing maintenance, and cybersecurity measures to protect data. Many brands jump into digital packaging without fully understanding the hidden costs, only to face unexpected challenges down the road.
Despite these hurdles, the cost of inaction is far worse. Manufacturers that hesitate to innovate risk falling behind competitors, facing regulatory penalties, and losing consumer trust. On the other hand, those that embrace sustainable and functional packaging gain a competitive edge.
Recyclable, refillable, and lightweight packaging solutions not only meet consumer expectations but can also lead to long-term savings by reducing material use and lowering transportation costs.
So, how can manufacturers manage these costs while staying ahead? Collaboration is key. Working closely with suppliers, leveraging government incentives, and adopting circular economy models can help offset expenses. The companies that take a strategic approach to packaging innovation, prioritizing both sustainability and financial viability, will be the ones that thrive in the evolving marketplace.
Welcome to Issue 7 of Sustainable Packaging Middle East & Africa. Enjoy the read!
Alphonse Okoth Senior Editor, FW Africa
COMPANY FEATURESKANEM AFRICA
Pioneering sustainable labeling solutions in the continent
MARKET TRENDS - SAFETY IN PHARMA PACKAGING
Securing the cure: Trends in safety in pharmaceutical packaging
COUNTRY FOCUS - SAUDI ARABIA
How Saudi Arabia is unboxing industrial growth, sustainability, and global competitiveness
PICK - CIRCULAR MODEL
The Curcular economy: An Age-Old Concept in a Modern World
Polyvinyl Chloride’s (PVC) resilience in pharmaceutical blister packaging
Company Website: www.fwafrica.net www.healthcaremea.com
Sustainable Packaging Middle East & Africa is published 4 times a year by FW Africa. Reproduction of the whole or any part of the contents without written permission from the editor is prohibited. All information is published in good faith. While care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of any action taken on the basis of information published.
www.dairybusinessafrica.com
www.sustainabilitymea.com
EVENTS CALENDAR
Labelexpo Europe 2025
16 – 19 September 2025, Fira Gran Via, Barcelona www.labelexpo-europe.com
Propak East Africa 2025
20 - 22 May 2025, Sarit Expo Centre, Nairobi, Kenya www.propakeastafrica.com
Plastic & Packaging Industry
29 - 31 May 2025
Expo Centre Lahore www.plastipackpakistan.com
AFMASS Food Manufacturing Expo Kenya & Eastern Africa Edition
2-4 July 2025
Sarit Expo Centre, Nairobi, Kenya www.afmass.com
Complast Kenya 2025
24 – 26 July 2025
Kenyatta International Convention Centre, Nairobi, Kenya www.complast.in/kenya
PackVision Expo 16 -18 May 2025
PIECC (Pune International Exhibition & Convention Centre), Moshi, Pune, India. www.packvisionexpo.com
Saudi Print & Pack 12 – 15 May 2025
Riyadh International Convention & Exhibition Center Riyadh, Saudi Arabia
Gulf Print & Pack Riyadh www.saudi-pp.com
Africa Food & Packaging Awards
July 4, 2025
Sarit Expo Centre, Nairobi, Kenya www.awards.foodbusinessafrica.com
Propak MENA 2025
2-4 June 2025
Egypt International Exhibition Centre (EIEC), Cairo, Egypt www.propakmena.com
Co-located with
No.1 Trade Shows for Food Service, Hospitality & Travel Industry in Africa
ANDRITZ commissions India’s largest fibreflow drum pulper at N.R. Agarwal Industries
INDIA - ANDRITZ has successfully launched a cutting-edge recycled fiber line at N.R. Agarwal Industries Ltd. (NRAIL) in Vapi, Gujarat, marking a major advancement in India's pulp and paper sector.
The installation features India’s largest FibreFlow drum pulper, with a daily processing capacity of 685 tonnes. This technology enables high-quality recycled fiber production for the largest coated duplex board machine in India.
The Prime FibreFlow Drum, a 32-meter-long unit with a 3.5-meter internal diameter, ensures efficient separation of contaminants with minimal fiber loss.
The line also integrates ANDRITZ’s PrimeScreen X with PrimeRotor for enhanced screening performance, reducing energy consumption and operational costs.
A compact Paper Machine Approach (PMA) system stabilizes pulp flow while optimizing space and energy use.
Integrated broke handling and fiber recovery systems further
boost efficiency by recovering usable fibers, minimizing waste, and supporting NRAIL’s sustainability goals.
Venkatesh, NRAIL’s President of Technical Operations, praised ANDRITZ’s expertise and emphasized the project’s role in enhancing production and sustainability.
He said, “We are delighted with the successful start-up of the recycled fiber line. The experts from ANDRITZ have been highly professional and supportive throughout the project.
“We are confident that the line will enhance our production capabilities and contribute to our sustainability goals.”
Founded in 1993, NRAIL is a leader in 100% deinked, woodfree recycled paper production, supplying duplex boards, writing and printing papers, and newsprint to domestic and international markets.
With this investment, NRAIL strengthens its commitment to innovation and environmental responsibility while ANDRITZ solidifies its presence in South Asia’s fast-growing paper industry.
Printcare opens state-of-the-art packaging facility in Nairobi, Kenya
KENYA – Printcare PLC, Sri Lanka’s leading packaging solutions provider, has launched a cutting-edge packaging facility in Nairobi, Kenya, marking a key milestone in its global expansion.
Strategically located in Nairobi, a growing hub for East African trade, the facility aims to support industries such as tea, apparel, horticulture, pharmaceuticals, and FMCG.
The plant utilizes advanced technology to produce premium packaging products, including mono cartons, corrugated cartons, and paper bags, thereby addressing Africa’s growing demand for eco-friendly, high-quality packaging.
Sustainability is central to the facility’s operations, with a focus on reducing carbon emissions through energy-efficient processes and sustainable materials.
This expansion aligns with Printcare’s broader mission to provide innovative packaging globally while reinforcing its reputation for quality and environmental responsibility.
Printcare’s choice of Nairobi as its regional base reflects the city’s growing status as a hub for international packaging firms.
Notably, Nairobi is also drawing other international packaging and supply chain players. Nexgen Packaging, a global supplier of garment trims and packaging solutions, recently established its African headquarters in the city.
Located in the Athi River Export Processing Zone, Nexgen’s facility signifies a substantial commitment to the continent. It complements the company’s existing operations in Egypt
and West Africa and positions Kenya as its primary production base in Africa.
Nexgen CEO Jim Welch emphasized the importance of investing in Africa’s growing manufacturing sector.
“Our investment in this new facility underscores how Nexgen is contributing to our customers’ current and future needs,” Welch said.
“With the growing demand for apparel, footwear, and home products made in Africa, Nexgen is excited to be leading the industry with the launch of this state-of-the-art, sustainable facility.”
GulfPack set to boost BOPP film production capacity in Saudi Arabia
SAUDI ARABIA – Gulf Packaging Industries (GulfPack), a leading manufacturer of biaxially oriented polypropylene (BOPP), cast polypropylene (CPP), and metallised films, is embarking on a major expansion project to increase its production capacity significantly.
As part of the expansion, GulfPack will install two state-ofthe-art BOPP production lines, each measuring 10.4 meters wide, at a newly established facility.
These additions will boost the company’s total BOPP film production capacity from 183,000 tonnes per annum (tpa) to 318,000 tpa. The first line is scheduled to be operational in 2026, and the second will come online in 2027.
The move underscores the company’s strategic focus on meeting global demand and supporting environmentally sustainable packaging solutions.
This latest investment builds on GulfPack’s recent growth momentum, reinforcing its commitment to innovation and sustainability.
The company aims to develop high-performance films that support recyclable mono-material structures, aligning with global trends toward circular economy models and reduced environmental impact.
GulfPack CEO Naif Alansari highlighted the significance of the expansion, “This expansion is a testament to GulfPack’s unwavering commitment to innovation, sustainability, and customer service.
“We have received an overwhelming response to our recent expansions in 2023–24, and with our customer base growing rapidly, demand for our high-performance films continues to surge globally.”
Currently exporting to over 75 countries, GulfPack plays a critical role in supplying packaging converters and fast-moving consumer goods (FMCG) companies worldwide.
Its advanced films are used in various applications, including food packaging, labeling, and industrial products.
Coca-Cola launches packaging collection hub to tackle waste in Nigeria
NIGERIA – Coca-Cola Nigeria Limited and its authorized bottler, Nigerian Bottling Company (NBC), have launched a new packaging collection hub in Lagos to enhance waste management and recycling efforts.
The facility, capable of processing up to 13,000 metric tonnes of plastic bottles annually, is a significant step in strengthening Nigeria’s plastics recycling infrastructure.
Speaking at the inauguration, Coca-Cola CEO Zoran Bogdanovic reaffirmed the company’s commitment to sustainability, emphasizing that the hub will help reduce waste, create jobs, and support local communities.
The initiative aligns with Coca-Cola’s global sustainability goals, which include incorporating 35–40% recycled content into its packaging and increasing the use of recycled plastic to 35% worldwide.
Luisa Ortega, President of Coca-Cola’s Africa Operating Unit, highlighted the company’s long-standing presence in Nigeria and its dedication to advancing collection and recycling through strategic partnerships.
“In addition to driving sustainability within the Coca-Cola System, this hub will serve as a key solution for plastic waste management,” Ortega stated.
The hub will facilitate the collection of PET bottles, process materials into clean PET bales, and support the production of recycled polyethylene (rPET) through third-party collaborations.
The project has received strong support from the government. Minister of Trade and Investment Dr. Jumoke Oduwole described it as a critical step toward sustainability, economic growth, and environmental responsibility, aligning with President Bola Tinubu’s vision for a self-sustaining Nigeria.
Lagos State Governor Babajide Sanwo-Olu’s representative praised NBC for prioritizing sustainability beyond profitmaking. At the same time, Minister of State for Industry, Sen. John Enoh, lauded the initiative’s potential to drive long-term environmental and economic benefits.
Coca-Cola aims to scale this model across Nigeria, fostering collective action toward a cleaner and more sustainable future.
Krones expands production with new bottling machine facility in India
INDIA – German packaging and bottling machine manufacturer Krones has commenced construction of a US$36.33 million bottling equipment manufacturing plant in Vemagal, Karnataka.
The project is expected to create approximately 550 jobs and is part of the broader US$118 billion investment initiatives announced at this year’s Global Investors Meet (GIM) Invest Karnataka event.
The Vemagal facility is designed to enhance Krones’ production capacity, contributing to the region’s economic growth and creating employment opportunities.
This expansion aligns with Krones’ sustainability strategy, unveiled in April 2024, which aims for net-zero greenhouse gas (GHG) emissions across its entire value chain by 2040.
In line with the Science-Based Targets initiative (SBTi), the company plans to reduce its emissions by 90% across Scopes 1, 2, and 3, offsetting the remaining 10% through verified carbon removal projects.
The new facility will integrate energy-efficient technologies
to minimize its environmental footprint while ensuring costeffective, high-quality manufacturing solutions for the growing Indian market.
With this strategic expansion, Krones reinforces its presence in India while supporting the global transition toward sustainable packaging and bottling solutions.
Meanwhile, in July last year, the company’s subsidiary, Krones Recycling, commenced business operations as a newly founded subsidiary with its headquarters in Flensburg, Germany.
The subsidiary will assume responsibility for all activities related to plastics recycling, while continuing to utilize Krones’ global production, sales, and service network.
Michael Gotsche, managing director of Krones Recycling, highlighted the advantages of the new company structure, stating, “Due to leaner processes and structures, we will be able to respond more quickly to changes in the constantly evolving recycling market.
Konza City pioneers Africa’s first automatic waste collection system
KENYA - Kenya’s Konza Technopolis has launched Africa’s first automatic solid waste collection system, marking a major leap in sustainable urban development.
Developed by Spanish firm Envac, the KES 1.17 billion (US$9.02m) system eliminates traditional garbage trucks, positioning Konza among the world’s most advanced cities in waste management.
The pneumatic waste collection technology features an underground vacuum pipeline network that transports waste at a rate of 70 km per hour to a central terminal, processing up to 40 tonnes of waste daily.
“Konza’s automatic waste collection system is the first of its kind in Africa,” explains Alice Obota, an electrical engineer involved in its installation and commissioning.
“It significantly reduces carbon emissions, speeds up waste processing, and prevents the environmental issues caused by overflowing bins and inefficient collection.”
A 14.8-kilometre pipeline connects 100 waste inlets near residential and office buildings, allowing waste to be sorted at the source into plastics, paper, mixed waste, and organics. Sensors automatically trigger waste suction when bins are full.
This innovation drastically reduces carbon emissions, improves sanitation, and prevents the overflowing bins and illegal dumpsites commonly seen in major African cities, such as Nairobi, Lagos, and Johannesburg.
By eliminating waste collection trucks, Konza’s system cuts
89 tonnes of carbon emissions annually. Industrial filters ensure the release of clean air, and the airtight design prevents odours and pest infestations.
Beyond waste management, Konza incorporates other ecofriendly initiatives, including a 30-acre solar farm that powers the city with renewable energy, thereby reducing its reliance on fossil fuels.
The city also recycles wastewater to WHO drinking water standards for irrigation, supporting tree-lined roads and green spaces.
With a goal of 70% tree canopy coverage, Konza enhances urban sustainability by reducing heat, improving air quality, and promoting a walkable environment. As a model smart city, it sets a precedent for future sustainable developments across Africa.
Smurfit Westrock opens innovation center in Morocco
MOROCCO - Smurfit Westrock, a global leader in sustainable packaging, has inaugurated its first African Experience Centre in Rabat, Morocco.
As part of a global network of 30 such centers, this facility reinforces the company’s commitment to innovation and sustainability.
Equipped with advanced design tools, including AI, predictive analytics, and virtual reality, the center provides a collaborative platform for businesses to develop cutting-edge packaging solutions.
Morocco’s Minister of Industry and Trade, Ryad Mezzour, praised the initiative for strengthening the country’s industrial ecosystem and fostering sustainability.
Ignacio Sevillano, CEO for Spain, Portugal, and Morocco, highlighted the center’s role in enhancing packaging strategies, while Chief Innovation Officer Arco Berkenbosch emphasized its access to Smurfit Westrock’s global R&D network.
Additionally, Morocco CEO Mounir Naciri announced a €5 million (US$5.40m) investment in the Rabat plant, bringing the company’s total investment in Morocco to over €40 million (US$43.19m).
The inauguration coincided with the Better Planet Packaging conference, where discussions focused on sustainability, decarbonization, and the European Green Deal’s impact on packaging.
In a related development, Smurfit Westrock introduced a 100% paper-based alternative to polyethylene stretch wrap.
Made from Nertop Stretch Kraft paper, the recyclable wrap offers superior energy absorption and humidity resistance.
Initially adopted in the UK by glass manufacturer Encirc, the wrap is produced at the Nervión paper mill in Spain.
With 100,000 employees in 40 countries, Smurfit Westrock continues to lead in sustainable packaging, operating 62 paper mills and over 500 packaging facilities worldwide.
Sweden’s DRS hits record 2.8B beverage containers recycled in 2024
SWEDEN
- Sweden’s Deposit Return System (DRS) has reached a historic milestone in 2024, with over 2.8 billion PET bottles and aluminum cans returned for recycling, a 6% increase from the previous year.
Operated by Returpack/Pantamera, the system now averages 271 containers recycled per person, reinforcing Sweden’s strong recycling culture.
Established over 40 years ago, Sweden’s DRS is among the world’s most efficient waste management systems, thanks to collaboration among beverage producers, retailers, waste authorities, and consumers.
Reverse vending machines in supermarkets and shops make recycling accessible, while a 1- to 2-SEK deposit refund per container incentivizes participation.
The system employs a closed-loop recycling approach, ensuring that collected PET and aluminum are transformed into new bottles and cans, thereby maintaining material value and reducing environmental impact.
In 2024 alone, the DRS prevented over 180,000 metric tonnes of CO₂ emissions, equivalent to the yearly emissions of a medium-sized Swedish city.
“In the DRS, PET bottles and aluminum cans stay in a closed recycling loop, which is crucial for achieving true circularity,” said Sara Bergendorff, Head of Sustainability and Quality at Returpack/Pantamera.
While Sweden’s 87.6% return rate is among the highest
globally, it remains just short of the 90% target set under EU recycling goals.
To bridge this gap, the government has approved an increase in deposit rates, effective January 2025, aimed at boosting returns and further reducing waste.
Beyond DRS, Sweden leads in waste management, diverting over 99% of household waste from landfills.
Recycling education starts early in schools, while municipalities provide clear guidelines to reinforce a national culture of sustainability.
As more countries adopt deposit return schemes, Sweden’s model serves as a global benchmark, demonstrating how welldesigned policies, infrastructure, and public participation can drive environmental progress.
Israel enforces graphic warnings to curb smoking
ISRAEL - Israel’s Ministry of Health has introduced draft regulations requiring graphic health warnings on tobacco products, marking a significant step in the country’s antismoking efforts.
For the first time in Israel, cigarette packs and other tobacco products will display visual warnings alongside existing textual health warnings.
The new regulations aim to highlight the dangers of smoking and secondhand smoke exposure. The rules will apply to a range of smoking products, including cigarettes, electronic cigarettes, hookahs, and tobacco for chewing or snuffing.
The graphic warnings will feature images of decayed organs, smokers on ventilators, and children exposed to cigarette smoke, reinforcing the severe health risks associated with tobacco use.
With this initiative, Israel joins a growing list of countries that require graphic warnings on tobacco products.
Notably, Israel will be one of the first countries globally to enforce a dual-warning system—both graphic and verbal—for electronic cigarettes and their components.
According to the proposed regulations, tobacco packaging must feature a graphic warning that illustrates the potential harms of smoking and a written health warning that explains its adverse effects.
Additionally, product labels must provide information on smoking cessation resources, including the Ministry of Health’s quitline and cessation services available through health funds.
Health Minister Uriel Busso emphasized the importance of the measure in reducing tobacco addiction, particularly among young people.
“This is another significant step in making tobacco products less appealing and preventing youth addiction to nicotine,” Busso stated.
Dr. Sharon Alroy-Preis, head of the Public Health Division at the Ministry of Health, emphasized the impact of graphic warnings on reducing smoking rates.
“Global studies have shown that graphic warnings on tobacco products are an effective deterrent,” she noted.
Borealis unveils recycled polyethylene for flexible packaging
AUSTRALIA - Borealis has introduced Borcycle M CWT120CL, an innovative recycled linear low-density polyethylene (rLLDPE) designed to enhance circularity in non-food flexible packaging.
This advanced material consists of 85% post-consumer recyclate (PCR) blended with 15% LLDPE booster, leveraging Borealis’ proprietary mechanical recycling technology.
Optimized for blown film applications, Borcycle M CWT120CL is suitable for stretch film, stretch hoods, and protective films used in agricultural and industrial packaging.
The material offers excellent stretchability, low gel content, and a balance of toughness and stiffness, ensuring durability without compromising performance.
Developed in partnership with Ecoplast, a Borealis Group member, the new rLLDPE grade has been in development since late 2022 and is expected to be commercially available starting in January 2025.
The innovation aligns with evolving regulations such as the EU Packaging and Packaging Waste Regulation, helping customers lower their carbon footprint and achieve sustainability targets.
Peter Voortmans, Commercial Director for Borealis Consumer Products Flexibles, emphasized the product’s impact, “With its impressive 85% post-consumer recyclate content, this new rLLDPE grade represents a major step on the path to a circular economy for plastics.”
“Borcycle M CWT120CL is a major step toward a circular economy for plastics, allowing customers to meet sustainability goals while maintaining high performance.”
The launch follows Borealis’ introduction of HC609TF, a high-stiffness polypropylene homopolymer designed for thermoforming applications like trays, cups, and containers.
HC609TF offers faster cycle times, excellent transparency, and recyclability, supporting reusable packaging structures that reduce waste.
Headquartered in Vienna, Borealis operates in over 120 countries, employing 6,000 staff members and driving innovation in sustainable polyolefins and recycled plastics to support a circular economy.
Epson SurePress achieves Idealliance Digital Press certification
USA - Epson’s SurePress digital label press lineup, including the SurePress L-4733AW and L-6534VW, has earned the Digital Press System Certification from Idealliance, a global authority on print and packaging standards.
This certification confirms that SurePress models, when paired with the Wasatch RIP (Raster Image Processor), meet Idealliance’s rigorous standards for color accuracy, print quality, and production reliability.
The program evaluates digital presses based on colorimetric precision, uniformity, repeatability, durability, and registration, ensuring industry-standard performance.
Mike Pruitt, Product Manager for SurePress at Epson America, highlighted the growing demand for color-accurate labels at competitive prices. He emphasized that this certification guarantees uniform print quality worldwide, stating,
"Wherever a customer is printing—whether in India or Indiana—this certification ensures SurePress models meet strict Digital Press System requirements, leading to customer satisfaction and fewer rejected orders."
By securing this certification, Epson reinforces its reputation for reliable label printing solutions, ensuring seamless coordination between its digital front-end, print engine, and media for superior color consistency across different production environments.
The Idealliance Digital Press Certification Program serves as a benchmark for assessing the capabilities of commercial inkjet production systems, from high-speed cut-sheet to web-based devices.
The certification reassures print professionals that Epson SurePress presses deliver standardized, high-quality color reproduction, which is crucial for maintaining brand integrity and ensuring supply chain reliability.
Jordan Gorski, Executive Director of Idealliance, praised Epson’s achievement, stating, "The SurePress certification highlights Epson’s dedication to excellence in print accuracy. Idealliance standards, such as G7, remain the foundation for color consistency and workflow alignment."
This certification reinforces Epson’s leadership in the digital label printing market, providing customers and label converters with greater confidence in achieving precise and repeatable color results, regardless of location or production scale.
Rwanda introduces an import levy to curb plastic pollution
RWANDA - Rwanda’s Ministry of Finance and Economic Planning has announced a 0.2% levy on imported goods packaged in plastic materials, effective July, to strengthen plastic waste collection and recycling.
This aligns with Rwanda’s 2019 ban on single-use plastics, which already imposes an environmental levy on locally packaged plastic products.
Previously, local manufacturers were paying Rwf120 per kilogram for plastic packaging, while imported plastic-packaged goods were exempt, creating an unfair price advantage.
Minister Yusuf Murangwa explained that the new levy ensures a level playing field by making importers financially responsible for managing plastic waste.
“The levy is timely because local manufacturers have been paying Rwf120 per kilogram for plastic packaging, while imported goods in plastic materials were exempt,” Murangwa explained.
Minister of Trade and Industry Prudence Sebahizi noted that imports from countries like Kenya and Uganda had avoided extra costs, making locally bottled water and plastic-packaged products more expensive.
With this levy, the prices of imported goods are expected to rise by 0.2%, encouraging consumers to consider alternative options.
While Rwanda enforces strict plastic regulations, the Rwanda Environment Management Authority (REMA) allows exemptions for essential sectors, including medical, agricultural, waste management, and construction industries.
Products like food and pharmaceuticals that require plastic for preservation are also permitted.
However, companies using plastic packaging are required to sign agreements with the Ministry of Environment to ensure proper collection and recycling of plastic waste.
By extending plastic waste responsibility to both local and foreign businesses, Rwanda reinforces its leadership in environmental sustainability in Africa.
The government’s latest initiative seeks to reduce plastic pollution, support recycling efforts, and drive fair competition within the market.
Saica Group to invest over US$110M in Indiana corrugated packaging plant
USA – Spain-based packaging giant Saica Group has announced plans to construct a state-of-the-art corrugated packaging manufacturing plant in Anderson, Indiana.
This will be the company’s second corrugated facility in the United States, marking a significant step in its broader US$800 million U.S. expansion strategy, which was unveiled earlier.
The newly approved investment, exceeding US$110 million (equivalent to more than €100 million), follows receipt of the green light from the company’s Board of Directors.
Construction is set to commence in May 2025, with the plant expected to begin operations by the fourth quarter of 2026.
Located in the City of Anderson, the plant will span nearly 350,000 square feet (around 32,500 square meters) and will be equipped for an annual production capacity of more than 1.2 million MSF (approximately 110 million square meters) of corrugated packaging.
The facility will house manufacturing, converting, and production lines, as well as a warehouse and modern office space.
Designed with scalability in mind, the plant will also serve as a backup site for Saica’s existing customers currently serviced from its Hamilton, Ohio, facility, enhancing supply chain resilience and regional logistics efficiency.
A key feature of the site is its direct connection to a railroad line, enabling more efficient paper roll deliveries and lower transportation costs.
The project is expected to generate significant employment opportunities in the region. In the first two years of operation, Saica anticipates hiring over 50 well-compensated full-time employees, with the workforce expected to exceed 100 once the plant reaches full production capacity in the years following startup.
This development reflects Saica’s long-term commitment to the U.S. market and reinforces its strategy of sustainable growth through advanced technology and high-efficiency production.
Sparklo collects 70M bottles and cans across MENA
UAE – Sparklo, a global cleantech leader, is transforming recycling and sustainability efforts across the MENA region.
Over the past year, the company expanded its network of reverse vending machines (RVMs), known as Sparklomats, to over 400 locations.
Since its inception, Sparklo has collected over 70 million plastic and aluminum recyclables, significantly reducing environmental waste.
Currently, Sparklo processes over 1.5 million bottles and cans weekly, advancing effective recycling practices to lower wasterelated environmental impacts.
What sets Sparklo apart is its innovative, incentive-driven approach to recycling. Using Sparklomats, users earn points for recycling bottles and cans, which can be redeemed for rewards such as discounted taxi rides with Yango, savings at Carrefour, and more.
This system has built a loyal, eco-conscious community while promoting sustainable habits.
To date, over 350,000 users have utilized Sparklo’s AIpowered Sparklomats, collecting over 57,500 kilograms of aluminum cans and more than 1.6 million kilograms of plastic items. One location set a record by collecting 11,000 recyclables in a single day.
Maxim Kaplevich, Sparklo’s founder and CEO, emphasized the importance of community-driven efforts, “Encouraging greener habits in local communities is key to making a real environmental impact.
“Sparklo’s innovative approach has already delivered impressive results, including reducing over 10.5 million kilograms of CO₂ emissions. By making recycling rewarding and accessible, we are conserving resources, minimizing landfill waste, and improving overall waste management efficiency.”
Sparklo has established partnerships with leading private and government organizations in the UAE, including ADNOC, Dubai Municipality, and Carrefour, among others.
The company’s operations extend beyond MENA to countries such as Saudi Arabia, Oman, Qatar, India, Thailand, Vietnam, Kazakhstan, and Georgia, where it continues to drive adoption of its AI-powered recycling technology and reduce carbon emissions.
Stora Enso expands packaging board production and advances battery innovation
FINLAND – Stora Enso has launched production on its newly converted consumer packaging board line at the Oulu facility in Finland, with initial customer deliveries expected by the second quarter of 2025.
The €1 billion (US$1.08bn) investment repurposes an idle paper machine into a high-capacity line producing folding box board (FBB) and coated unbleached kraft (CUK).
With an annual capacity of 750,000 tonnes, the facility is expected to break even on EBITDA by the end of 2025 and reach full capacity by 2027, generating approximately €800 million (US$866.39m) in annual sales.
This expansion reinforces Stora Enso’s position in renewable packaging, particularly in the food and beverage sectors across Europe and North America.
CEO Hans Sohlström highlighted the new line’s modernity and cost efficiency, stating that it will transform the Oulu site into an integrated mega-facility, thereby enhancing operational flexibility.
The upgrade complements an earlier 2021 conversion and
Mohinani
boosts production of unbleached pulp, kraftliner, and consumer board.
Wood consumption at the site is expected to rise to 3.5 million cubic meters annually, supported by local sourcing and Stora Enso’s recent acquisition of Junnikkala sawmills.
Additionally, Stora Enso has joined ATENA+, an EU Horizon Europe project advancing sodium-ion battery (SIB) technology.
The four-year initiative, launched in January 2025, brings together 12 partners to develop sustainable and cost-effective energy storage solutions.
Stora Enso contributes Lignode®, a wood-based anode material from EU-sourced lignin, which reduces reliance on graphite and enhances circularity.
Through its packaging and battery innovations, Stora Enso continues to drive sustainable industrial advancements, aligning with EU Green Deal objectives and strengthening Europe’s clean energy transition.
secures US$37M IFC loan to boost PET recycling in West Africa
GHANA - Mohinani Group has partnered with the International Finance Corporation (IFC) to enhance PET plastic waste recycling in Ghana and Nigeria.
Through a US$37 million loan, Mohinani’s subsidiaries, Polytank Ghana Limited and Sonnex Packaging Nigeria Limited, will establish PET recycling plants in both countries.
Each facility will have an annual capacity of 15,000 tonnes of recycled polyethylene terephthalate (rPET) resins, thereby reducing reliance on virgin PET resins in food and beverage packaging.
The initiative will source 90% of its raw materials from local plastic collection businesses, creating over 4,000 jobs and supporting economic empowerment, particularly for women and young people.
According to Roshan Mohinani, Strategy and Transformation Manager, the project aims to close the bottle-to-bottle recycling loop in Africa, thereby improving lives through job creation.
Beyond employment, the recycling plants will save Ghana and Nigeria approximately US$21 million annually on plastic resin imports.
PET, widely used in food and beverage containers, contributes significantly to plastic waste. Recycling it reduces pollution, lowers greenhouse gas emissions, and decreases reliance on virgin plastics.
IFC, a member of the World Bank Group, will also provide advisory services to ensure sustainable operations and compliance with environmental standards.
The project aligns with IFC’s strategic goals of mitigating climate change, creating jobs, and driving economic transformation in West Africa.
It also supports the World Bank Group’s Climate Change Action Plan 2021-2025, which prioritizes reducing virgin plastic use and emissions in the packaging sector.
Dahlia Khalifa, IFC Regional Director for Central Africa and Anglophone West Africa, emphasized that the plants will recycle up to 30,000 tons of PET waste annually, protecting the environment while replacing plastic imports with locally recycled materials.
Indian beverage industry challenges PET bottle recycling mandate
INDIA - India’s beverage industry is considering legal action against a government mandate requiring PET bottles to contain 30% recycled food-grade plastic starting April 1.
Industry leaders argue that the sudden enforcement, coupled with inadequate recycling infrastructure, could lead to supply shortages and higher costs.
The Ministry of Environment, Forest & Climate Change issued the directive for category-1 packaging, impacting manufacturers of soft drinks, bottled water, and juices.
PET bottles, which account for 70% of India’s beverage packaging, are favored for their cost-effectiveness and transportability.
Executives warn that India lacks the necessary recycling capacity to meet the new requirements. Bisleri International CEO Angelo George called for a phased approach, starting with 10-15% recycled content and increasing gradually as FSSAIapproved rPET production expands.
He also noted that Bureau of Indian Standards (BIS) guidelines
on rPET remain in draft form, complicating compliance.
If the mandate is enforced, the industry anticipates PET bottle shortages, material scarcity, and a 30% cost increase, potentially passed on to consumers. Smaller companies may turn to uncertified recyclers, raising safety concerns.
Despite industry appeals, the government is unlikely to extend the deadline, arguing that businesses have had over two years to prepare. The regulation also mandates a 10% annual increase in recycled content, reaching 60% by 2028–29.
With rising demand due to an early summer, companies may need to import recycled materials, further increasing costs.
Industry leaders urge the government to reconsider the timeline, citing the EU’s phased compliance model targeting 2030.
They have urged the government to reconsider the timeline, citing the European Union’s phased approach, which targets full compliance by 2030.
Huhtamaki secures golden license for US$29.76M fiberboard plant in Egypt
EGYPT - The Egyptian Cabinet has granted Huhtamaki Egypt a golden license to establish a state-of-the-art fiberboard packaging factory.
This approval, made during the 28th ministerial meeting, reflects Egypt’s commitment to sustainable industrial growth.
Located in Sadat City, Menoufia Governorate, the 21,700-square-meter facility will manufacture fruit containers, cup holders, and egg cartons.
The project, valued at EGP 1.5 billion (US$29.76m), includes €24 million (US$24.70m) in foreign investment. Huhtamaki plans to export 70% of its production while sourcing 70% of its components locally, reinforcing Egypt’s role in sustainable packaging innovation.
In parallel, Huhtamaki India, in partnership with the Finnish Embassy and the Confederation of Indian Industry (CII), hosted the second Think Circle Forum in New Delhi.
The event marked the launch of Design for Recycling Guidance for Films and Flexible Packaging, part of the India Plastics Pact (IPP).
Introduced in December 2024, these guidelines provide brands with strategies to transition to recyclable materials, emphasizing mono-material designs, the elimination of harmful pigments, and recyclable barrier layers.
The forum featured a panel discussion on circular packaging, with experts from Godrej Consumer Products, Banyan Nation, and Huhtamaki India.
Finland’s Ambassador to India, Kimmo Lähdevirta, highlighted the synergy between Finnish sustainable design and India’s innovation ecosystem in advancing circular packaging.
Lähdevirta remarked, “Finland’s expertise in sustainable design, combined with India’s innovative ecosystem, can set global benchmarks for circular packaging solutions.”
Seema Arora, Deputy Director General of CII, emphasized that the India Plastics Pact fosters sustainable practices in the FMCG industry. Think Circle continues to drive global collaboration for achieving circularity in packaging.
EU adopts Packaging and Packaging Waste Regulation for sustainable procurement
EUROPE - The European Union (EU) has formally enacted the Packaging and Packaging Waste Regulation (PPWR), a landmark policy aimed at reducing dependence on primary raw materials and ensuring that all packaging in the EU market is economically recyclable by 2030.
Taking effect in February, PPWR supports the EU’s goal of climate neutrality by 2050, emphasizing the safe integration of recycled plastics into packaging.
The regulation standardizes manufacturing, recycling, and reuse across member states, while minimizing environmental and health risks associated with packaging waste.
A major component of the regulation is Green Public Procurement (GPP), which is expected to drive sustainability in packaging-related public contracts.
By February 2030, the European Commission will introduce mandatory minimum requirements for procurement, ensuring sustainability criteria are embedded in technical specifications, selection criteria, and performance conditions.
Article 63 of PPWR emphasizes the importance of sustainability-based procurement while protecting contracting authorities from excessive costs.
The regulation also ensures that market conditions remain fair, preventing distortions and unfair competition.
Additionally, the PPWR strengthens packaging waste management obligations, reinforcing the EU’s commitment to waste reduction and circularity.
Meanwhile, the Dutch government is reconsidering its surcharge on single-use plastic packaging, initially introduced in July 2023 to encourage the adoption of sustainable packaging alternatives.
A policy review suggests that the levy has failed to drive significant behavioral change, with many businesses passing the cost on to consumers rather than reducing plastic use.
Under the policy, foodservice and retail outlets set their own surcharge levels, leading to inconsistent pricing. Many supermarkets imposed a mere €0.01 per item, failing to deter plastic consumption.
A mandatory €0.25 per container charge, set to take effect on January 1, 2026, is under review, with policymakers assessing its effectiveness in promoting reuse.
USA – Systech, a Markem-Imaje and Dover company specializing in digital identification and traceability software, has launched UniSecure ArtAI, an advanced AI-powered authentication technology designed to enhance brand protection, ensure packaging quality, and safeguard patients.
As a fully cloud-based SaaS solution, ArtAI leverages existing packaging artwork, combined with AI-driven applications such as machine vision, machine learning, and neural networks, to deliver real-time authentication, forensic analytics, and quality control for life sciences and pharmaceutical brands.
Sreedhar Patnala, General Manager at Systech, emphasized the innovation’s impact, “ArtAI is a groundbreaking solution that reinforces our commitment to tackling counterfeiting, diversion, and packaging quality challenges.
Counterfeit medicine trafficking is one of the fastest-growing criminal enterprises, with the illicit and substandard drug market generating an estimated €412 billion (US$443.90b) annually, according to the National Institutes of Health.
Brands also face challenges from false counterfeits—authentic products that are mistaken for fake due to flaws in packaging inspection.
ArtAI addresses these concerns by enabling pre-shipment detection of packaging inconsistencies and providing corrective analytics for quality control.
The technology uses machine vision and pattern recognition to create a digital blueprint of key packaging artwork features, ensuring precise verification and rigorous quality inspections.
ArtAI is designed for effortless deployment, requiring no changes to packaging or hardware integration.
Its mobile-friendly application allows for simple product scanning, while an AI-powered forensic platform quickly identifies issues and supply chain threats.
With advanced analytics and reporting, ArtAI minimizes the resources needed to identify, investigate, and resolve critical packaging challenges.
The solution offers a dual-layer approach to brand protection, ensuring both pre-market quality control and post-market security for pharmaceutical and life sciences companies.
Classic Kellogg’s Toasted Corn Flakes in Fresh Packaging
Kellanova has introduced a refreshed packaging design for its iconic Kellogg’s Toasted Corn Flakes – Toasted Golden Flakes, maintaining the product’s legacy of quality and freshness.
The breakfast staple now comes in a protective plastic flat pouch, securely housed within a sturdy 750g folded carton box.
The outer packaging features the recognizable Kellogg’s branding in bold red lettering, accompanied by an appetizing image of a bowl filled with crispy, golden cornflakes—underscoring the brand’s commitment to freshness and taste.
Cappy Still 100% Tropical Fruit Juice Blend
Coca-Cola has introduced its Cappy Still 100% Tropical Fruit Juice Blend in a sleek, transparent 1.5L plastic bottle, designed to showcase the juice’s rich, vibrant color and natural appeal.
The bottle’s ergonomic shape ensures easy handling and pouring, while a secure screw-on cap preserves freshness and prevents spills.
The back label provides essential product details, including nutritional information, ingredients, and storage instructions. The packaging is both lightweight and recyclable, aligning with Coca-Cola’s sustainability efforts.
Capri Sun unveils first-ever singleserve bottle
For the first time in 20 years, Capri Sun is introducing a single-serve bottle, marking a significant expansion for the iconic juice brand.
Parent company Kraft Heinz announced that the new 12-ounce resealable bottle is designed for on-the-go consumers, particularly those frequenting convenience stores.
While the brand is embracing this new packaging format, Kraft Heinz confirmed that Capri Sun’s signature pouch will remain available, ensuring loyal fans can continue to enjoy their favorite juice in its original form.
Jacobs Coffee revamps 3in1 Range with sustainable packaging
Jacobs Coffee has unveiled a refreshed and expanded 3in1 coffee range, featuring a more sustainable packaging design aimed at reducing environmental impact.
The updated box has been resized to minimize material use, leading to a 20.1% reduction in CO₂ emissions.
This eco-friendlier approach aligns with Jacobs’ broader sustainability strategy, reinforcing the brand’s commitment to reducing its environmental footprint. By adapting to consumer demand for more sustainable choices, Jacobs Coffee continues to balance convenience with responsible packaging innovation.
Royco Beef Casserole with Rosemary Cook-In Sauce
Mars South Africa has expanded its Royco range with the launch of Royco Beef Casserole with Rosemary Wet Cook-In Sauce, packaged in a convenient 415g pouch designed for effortless cooking.
The pouch enhances ease of use with its practical, easy-pour design, making meal preparation simple and mess-free.
With "Beef Casserole with Rosemary" clearly labeled on the front, along with the 415g net weight, consumers can easily identify the product.
Amcor’s 2oz retort bottle for shelfstable beverages
Amcor, in collaboration with Insymmetry, has introduced an innovative 2oz retort bottle, designed to meet the growing demand for durable, shelf-stable packaging.
The bottle is the first to incorporate Amcor Rigid Packaging’s (ARP) proprietary StormPanel technology, allowing it to withstand high-pressure retort sterilization while preserving product integrity and premium aesthetics.
Tailored for low-acid, shelf-stable beverages such as coffee and dairy-based drinks, this solution provides manufacturers with a cost-effective, scalable alternative to aseptic processing.
kanem AFRICA
Pioneering sustainable labeling solutions in the continent
Africa’s label printing industry is experiencing rapid growth, fueled by the expansion of key sectors such as food and beverage, pharmaceuticals, cosmetics, and logistics. Businesses are increasingly seeking high-quality, durable, and sustainable labeling solutions, driving demand for advanced printing technologies—including digital, flexographic, and hybrid printing.
The continent’s growing middle class, rising consumer expectations, and evolving regulatory requirements for product labeling have further accelerated the need for sophisticated labeling solutions. Bridging this gap is Skanem Interlabels Nairobi Limited, a company at the forefront of labeling innovation. Located in Tilisi, on the outskirts of Nairobi, Kenya, Skanem Africa provides labeling solutions across seven key sectors: automotive, personal care, food, beverage, pharmaceuticals, industrial, and home care.
In an interview with Sustainable Packaging
walk around the new facility during the official openning ceremony
Middle East & Africa Magazine, Richard Gathenya, Head of Operations at Skanem Africa, discusses the company’s rich history, expansion strategies, technological advancements, and the challenges of operating in Africa’s dynamic market.
A STORY OF GROWTH AND EXPANSION
For over two decades, Skanem Africa has been a leader in the labeling industry, growing alongside its customers and expanding its production capabilities to meet increasing demand. Initially operating from a facility in the Nairobi’s industrial area, the company faced space constraints that hindered its ability to scale efficiently. That led to the need to look for a bigger space for a better facility.
The company then relocated to a new 85,000 sq. M state-of-the-art facility in Tilisi, which was both strategic and necessary. “Our previous premises felt like a tight suit,” says Sachen Gudka, Managing Director of Skanem Africa. “We needed room to grow, innovate, and make a real impact. This new space allows us to do just that.”
The move doubled Skanem’s production
capacity and provided an opportunity to reinforce the company’s sustainability goals. “This IFC-Edge certified facility is more than just a factory—it’s a symbol of innovation and responsibility,” says Gathenya. “We’ve designed it to optimize workflow, improve efficiency, and reduce our environmental footprint.”
Beyond Nairobi, Skanem Africa has expanded its reach across East and Southern Africa. In 2024, the company established a new manufacturing plant in Dar es Salaam, Tanzania, bringing production closer to key markets such as Malawi, Zambia, Zimbabwe, and the Democratic Republic of Congo.
“Expanding into Tanzania was a strategic move to enhance accessibility and streamline logistics for our customers,” Gudka explains. “It allows us to serve our Southern Africa clients more efficiently while reducing lead times and transportation costs.”
By establishing a fully-fledged manufacturing plant in Dar es Salaam, Skanem has significantly reduced its reliance on Nairobi for exports to Tanzania, Malawi, Zambia, and Zimbabwe. This strategic move enhances operational efficiency and strengthens regional supply chains by
IN NUMBERS THE SIZE OF SKANEM NEW FACILITY 85,000 Sq.M
Sachen Gudka, CEO of Skanem Africa Ltd
WE NOW HAVE FIVE HIGH-SPEED FLEXOGRAPHIC PRINTING PRESSES, EACH CAPABLE OF HANDLING 10-COLOR
JOBS AT
SPEEDS OF UP TO 200 METERS PER MINUTE.
customers. Reduced logistics expenses translate into better pricing structures, allowing businesses to optimize their packaging investments while maintaining high-quality standards.
Beyond business efficiency, the expansion has created local job opportunities, reinforcing Skanem’s commitment to regional economic growth. By investing in Tanzania, the company is strengthening its footprint in East and Southern Africa, contributing to the region's skill development and industrial growth.
enabling direct production and distribution from Tanzania.
The new facility has also shortened delivery timelines for customers across Southern Africa. By eliminating the need for cross-border shipments from Nairobi, businesses in the region benefit from faster turnaround times, improving their ability to meet market demands more efficiently.
Additionally, lower transportation costs have made Skanem’s products more affordable for
To further improve service delivery, Skanem Africa also opened a distribution center in Uganda, ensuring faster deliveries within the East African Community (EAC). “Every decision we make is about serving our customers better,” Gathenya adds. “When we expand, we do so with efficiency and sustainability in mind.”
INNOVATION AT THE HEART OF OPERATIONS
Walking through Skanem Africa’s Tilisi facility, one is immediately struck by the meticulously
Gathenya, Operation Manager, Skanem Africa
designed, linear workflow, a layout that optimizes efficiency at every production stage. The factory hums with precision as raw materials enter one end and move seamlessly through the various slitting, printing, finishing, and packaging stages before emerging as high-quality labels ready for shipment.
Every step in this process is carefully orchestrated to reduce material wastage, maximize production speed, and maintain stringent quality control standards. "This facility was built with a purpose," says Gathenya. "From day one, we envisioned a space that eliminates inefficiencies and ensures a smooth flow of operations, allowing us to serve our customers faster and more effectively than ever before."
“We now have five high-speed flexographic printing presses, each capable of handling 10-color jobs at speeds of up to 200 meters per minute,” says Gathenya. “This setup allows us to produce 800 jobs monthly, ensuring quick turnaround times while maintaining the highest quality standards.”
The company’s emphasis on precision and consistency is evident in its quality control laboratory, where rigorous testing is conducted at every production stage. “Our customers rely on us for consistency,” says Gathenya. “From raw materials to the final product, we ensure every label meets strict durability and regulatory standards.”
PIONEERING SUSTAINABILITY IN LABELING
Skanem Africa’s commitment to sustainability goes beyond production efficiency. The company has integrated green energy solutions into its operations, making its Tilisi facility IFC Edge Certified. “The entire facility runs on solar power
during the day, supplying up to 90% of our energy needs,” explains Gudka. “We’ve also replaced conventional UV lamps with energy-efficient LED lighting, cutting our electricity consumption by 50%.”
Another pillar of Skanem’s sustainability strategy is responsible sourcing. The company ensures that all raw materials come from Forestry Stewardship Council (FSC)certified suppliers, promoting ethical forestry practices. “We take sustainability seriously,” adds Gudka. “It’s not just about compliance—it’s about making a difference. Our goal is to lead the shift towards responsible packaging in Africa.”
In line with its sustainability efforts, Skanem Africa also holds the prestigious Brand Reputation Certification Global Standard (BRCGS) certification, a globally recognized standard for food-safe packaging. “We want our customers to have confidence in our products,” says Gathenya.
EMPOWERING PEOPLE: THE TEAM BEHIND THE LABELS
While Skanem Africa’s technological advancements and sustainability initiatives are impressive, the company’s people drive its success. The company places a strong emphasis on employee well-being and professional growth. “All our employees transitioned with us from Mombasa Road to Tilisi,” says Gudka. “That was non-negotiable. We are a family, and families stick together.”
The new facility includes a modern cafeteria and breakout spaces to ensure employees have a comfortable environment. Additionally, continuous training programs are in place to
Noregian Ambassador to Kenya attending Skanem factory launch
keep staff updated with the latest industry trends and innovations. “Moving here felt like stepping into the future,” says a staff. “The space, the equipment—it all makes our work easier and more efficient.”
SERVING A DIVERSE MARKET WITH EXCELLENCE
Skanem Africa offers a comprehensive range of labeling solutions, combining functionality with visual appeal across various industries. Its pressure-sensitive labels (PSL) are preferred in the beverage and personal care sectors, providing a sleek, self-adhesive finish that enhances branding while ensuring durability.
For the soft drinks market, Skanem Africa
produces wrap-around labels, widely used by multinational beverage brands. These labels offer a cost-effective, high-volume solution and maintain vibrant designs even in cold storage conditions.
To accommodate uniquely shaped bottles, the company manufactures shrink sleeves, which conform seamlessly to contoured packaging. This full-body labeling option provides maximum design flexibility and 360-degree branding, making it an excellent choice for premium beverages, personal care, and specialty products.
Additionally, in-mold labels are integrated into plastic containers, ensuring long-lasting durability and resistance to moisture, scratches, and peeling. This technique is particularly beneficial for food packaging and household products, where longevity and aesthetics play crucial roles.
A TRUSTED PARTNER FOR GLOBAL AND REGIONAL BRANDS
The company serves various customers from multinational corporations such as Coca-Cola, Heineken, and Diageo to local and regional brands across multiple industries, including food and beverage, pharmaceuticals, and personal care. The company works closely with established global players and emerging businesses, ensuring customized labeling solutions tailored to each brand’s needs. "Our goal is to provide labels that
meet industry standards and enhance brand visibility and consumer engagement," says Gathenya.
“We’re not just printing labels; we’re telling brand stories,” he adds. “A good label catches the eye, communicates vital information, and enhances the overall packaging experience.”
With 50% of its production exported, Skanem Africa has positioned itself as a key player in the regional labeling industry. The company's strategic expansion into Tanzania and the establishment of a distribution center in Uganda have significantly reduced lead times and improved service efficiency. "We are not just meeting demand; we are anticipating market needs and adapting to provide seamless solutions for our customers across Africa," says Gathenya. Our ability to scale while maintaining quality and sustainability sets us apart in a competitive landscape."
LOOKING TO THE FUTURE
Skanem Africa has strategically designed its Tilisi facility with room for future expansion. The company is actively exploring the introduction of next-generation printing technologies and further sustainability innovations. “The future is about responsible packaging,” says Gudka. “We will continue
to invest in technology, efficiency, and customer-centric solutions. The goal is not just to grow but to lead.”
As the sun sets over Skanem Africa’s Tilisi plant, the steady hum of the printing presses reminds us of the company’s unwavering commitment to innovation, sustainability, and customer satisfaction. With a strong leadership team, cuttingedge technology, and a sustainability-first mindset, Skanem Africa is not just printing labels—it’s shaping the future of packaging in Africa.
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Gathenya, Operation Manager, Skanem Africa
Securing Cure
BY
Trends in safety in pharmaceutical packaging
In the high-stakes world of pharmaceuticals, packaging is more than just a vessel—it’s a critical layer of defense. As the global pharmaceutical market continues to expand, projected to surpass US$1.6 trillion by 2028 by the latest World Preview report published by Evaluate Ltd., the spotlight has increasingly shifted to the role of packaging in ensuring drug safety, efficacy, and integrity.
Innovations in pharmaceutical packaging are evolving to meet regulatory standards and anticipate emerging threats such as counterfeiting, contamination, and patient misuse. This article delves into the latest trends in safety in pharma packaging, the strategies manufacturers are deploying, and the real-world impacts of these advancements.
SERIALIZATION AND TRACK-AND-TRACE: COMBATING COUNTERFEITS
Counterfeit drugs remain one of the most pressing global health threats, especially in low-to-middleincome countries. The World Health Organization estimates that 1 in 10 medical products in these regions is substandard or falsified. To address this, serialization and track-and-trace technologies have become mandatory in many regions under laws such as the U.S. Drug Supply Chain Security Act (DSCSA) and the EU Falsified Medicines Directive (FMD).
Serialization assigns a unique identifier to each saleable unit, enabling drugs to be tracked across the supply chain. Manufacturers like Pfizer and Roche
deploy end-to-end digital serialization platforms integrated with cloud systems to provide real-time authentication at every stage. Pfizer’s Serialized Product Verification system links each unit to its manufacturing and distribution history, allowing pharmacists to scan and verify products instantly.
advanced data matrix codes on secondary packaging, which, when combined with blockchain-enabled verification tools, has improved product traceability and reduced the time needed for recall processes. Both companies have also invested in integrating mobile scanning features, enabling patients to verify product authenticity at the point of use, thereby increasing transparency and patient confidence.
to a 65% drop in counterfeit incidents in pilot programs and improved recall response times by over 40%. After implementing their Serialized Product Verification system, Pfizer reported a 50% decrease in pharmacylevel product authentication issues. In comparison, Roche noted a 35% reduction in recall execution time and a 20% increase in patient-reported confidence in medication authenticity through its blockchain-verified data matrix system.
TAMPER-EVIDENT AND TAMPER-RESISTANT PACKAGING
Another critical innovation is the proliferation of tamper-evident and tamper-resistant features. These
ALPHONSE OKOTH
QR CODES LINKED TO BLOCKCHAIN SYSTEMS PROVIDE SECURE, TAMPER-
PROOF RECORDS OF A DRUG’S SUPPLY CHAIN JOURNEY, IMPROVING TRACEABILITY AND REDUCING COUNTERFEITING RISKS.
include breakable seals, shrink bands, blister packs with destructible lids, and containers that show visible signs of opening.
Companies like Amcor and Constantia Flexibles invest In next-generation films and coatings that enhance resistance and visibility. In the pharmaceutical sector, Amcor’s “AmLite Ultra Recyclable” has been adopted by European generic medicine manufacturers to package oral solid doses. This solution uses high-barrier, metal-free materials that maintain drug efficacy by protecting against moisture and oxygen and allow for immediate visual detection of tampering.
Constantia Flexibles has developed EcoLamHighPlus, a mono-material laminate used for blister packaging in antibiotics and over-the-counter medications. It offers enhanced tamper evidence and improved oxygen barrier properties, helping Southeast Asian clients reduce spoilage rates during monsoon seasons.
These innovations have contributed to a 22% decrease in tampering complaints in Amcor’s pharmaceutical supply chains and helped Constantia’s clients improve product stability in humid regions by up to 30%, leading to longer shelf life and fewer product recalls.
The European Medicines Agency reported a rise in compliance with tamper-proof standards from 72% in 2019 to 91% in 2023. Additionally, Amcor’s partners reported a 20% decline in returned products due to suspected tampering,
while Constantia Flexibles noted improved shelf stability in high-temperature environments, reducing temperaturerelated degradation complaints by 18%.
According to a survey of EU pharmaceutical retailers, implementing clear visual cues for tamper evidence has also increased consumer confidence and reduced helpline queries related to product safety by 25% over three years.
SMART AND CONNECTED PACKAGING
Smart packaging has taken center stage as pharmaceutical manufacturers seek to simultaneously enhance safety and patient engagement. For example, NFC (Near Field Communication) tags are now embedded in prescription bottles and blister packs, allowing patients and pharmacists to access real-time product information using smartphones.
QR codes linked to blockchain systems provide secure, tamper-proof records of a drug’s supply chain journey, improving traceability and reducing counterfeiting risks. Time-temperature indicators (TTIs) are widely used in biologic drug packaging to visually confirm whether the product has been exposed to temperature excursions during transit or storage.
Adherence-tracking blister packs, such as those developed by Schreiner MediPharm, include microcircuits that detect pill removal and sync with digital health platforms, enabling tailored patient support. Collectively, these innovations are transforming packaging into an active tool for safety assurance, regulatory compliance, and patient empowerment.
Firms like Pharma Sentinel and Schreiner MediPharm lead the development of connected packages that monitor doses
and send real-time alerts. Pharma Sentinel's mobile-connected blister packaging, for example, uses embedded sensors and cloud connectivity to track patient adherence and generate reminders via smartphone apps.
Schreiner MediPharm’s 'Smart Blister Wallet' integrates printed electronics to log each pill’s removal, enabling clinicians to access adherence data remotely and adjust therapy as needed. Aptar Pharma’s smart inhalers and nasal sprays incorporate digital sensors that track dosage frequency and transmit usage data through Bluetooth-enabled mobile apps.
These systems are especially valuable in chronic care management, where real-time insights support personalized medicine, reduce misuse, and foster better patient-healthcare provider communication.
A 2022 MIT study found smart blister packs improved adherence by 28% over six months among chronic disease patients. This improvement translated into fewer hospital readmissions, better disease control, and enhanced therapy outcomes, particularly in conditions like hypertension, diabetes, and asthma.
The study also noted that digital blister packs significantly boosted communication between patients and healthcare providers, leading to faster treatment adjustments and increased patient satisfaction. In pharmaceutical trials, adherence-linked data from smart packaging enabled more accurate efficacy measurements and reduced dropout rates by 17%.
AI AND DIGITAL TWINS FOR QUALITY ASSURANCE
AI is transforming quality control in pharmaceutical packaging through real-time inspection, predictive analytics, and adaptive learning. Advanced machine vision systems, powered by AI algorithms, can now detect micro-defects in seals, labels, and blister cavities with higher accuracy and speed than human inspectors. These systems can identify anomalies such as incorrect pill placement, print smudges, or microtears in foil—all of which could compromise drug safety.
Digital twins, virtual models of packaging lines, simulate equipment behavior to forecast malfunctions, optimize performance, and reduce downtime. Companies like Merck KGaA and Novo Nordisk have integrated AI-powered inspection into their high-speed filling and sealing lines, achieving a 50% reduction in batch rejections due to packaging flaws.
The use of digital twins has also allowed manufacturers to run virtual trials, minimizing material waste and accelerating time-to-market for new products while maintaining stringent quality standards.
Merck KGaA and Novo Nordisk use AI-powered vision systems to verify seal integrity and label. Merck has
implemented hyperspectral imaging combined with deep learning algorithms to inspect seal quality at a pixel level, enabling the detection of invisible contaminants and microleaks in sterile drug packaging.
Novo Nordisk employs AI-powered optical character recognition (OCR) systems to validate multilingual label text in real-time, reducing labelling errors that could lead to adverse events or regulatory recalls. Both companies report increased throughput and compliance rates, with Merck reducing false-positive rejection rates by 40% and Novo Nordisk cutting labeling-related deviations by 35%.
Deloitte reports that AI use in packaging QA has reduced defective packaging incidents by up to 50%. Merck KGaA's implementation of hyperspectral imaging with AI has enabled a 40% reduction in false-positive rejects, minimizing unnecessary product waste and improving operational efficiency.
Novo Nordisk’s multilingual label verification systems have cut labeling deviations by 35%, leading to fewer compliance incidents and a 22% reduction in regulatory inspection findings. Across the industry, these AI applications have also accelerated time-to-market by streamlining quality checks and reducing manual inspection
labour by 30%, according to a 2023 industry benchmarking survey by EY.
CHILD-RESISTANT AND SENIORFRIENDLY DESIGNS
Balancing safety with usability remains challenging, especially for medications used in households with children or elderly patients. Child-resistant (CR) packaging is now a baseline requirement in many jurisdictions, but manufacturers are also innovating to enhance accessibility for seniors.
Companies such as Berry Global and Gerresheimer are designing CR caps with ergonomic features, tactile indicators, and audible clicks to reassure users of proper closure. Multi-layer blister packs with push-through and peel-push mechanisms are gaining popularity for combining security and ease of use.
These designs have drastically reduced accidental pediatric poisoning cases. According to the U.S. Consumer Product Safety Commission, child poisoning incidents from pharmaceutical products have declined by 30% between 2012 and 2022, largely due to improved CR packaging.
LOOKING AHEAD: WHERE INNOVATION MEETS RESPONSIBILITY
The future of pharmaceutical packaging lies at the intersection of innovation, safety, and sustainability. As patient-centered care becomes a priority, packaging will play an increasingly active role in protecting medicines and enhancing their delivery and monitoring. Companies that embrace intelligent design, integrated digital tools, and global safety compliance are poised to lead in this era.
However, these advances also raise important questions: How can we scale smart packaging in low-resource settings? Will stricter global safety norms raise drug prices? And how can manufacturers ensure data security in connected packaging ecosystems?
Answering these questions will require collaboration across the packaging supply chain, regulators, healthcare providers, and patients. What’s clear is that pharmaceutical packaging is no longer an afterthought—it’s an integral part of drug safety, access, and efficacy. SPMEA
Schreiner Medipharm's tamper proof syringe
Packaging FUTURE
THE
BY ALPHONSE OKOTH
SHow Saudi Arabia is unboxing industrial growth, sustainability, and global competitiveness
audi Arabia’s packaging industry is experiencing unprecedented growth, driven by rising consumer demand, economic diversification under Vision 2030, and the rapid expansion of food and beverage, pharmaceuticals, and e-commerce sectors. According to a 2023 report by Mordor Intelligence, the domestic packaging market—valued at approximately US$10.9 billion in 2022—is projected to reach US$16.3 billion by 2030, reflecting a compound annual growth rate (CAGR) of 5.5%.
Plastic packaging remains dominant, owing to abundant raw materials and strong petrochemical integration. However, as environmental awareness grows, paper-based and sustainable alternatives are rapidly gaining ground. To meet surging demand, production capacity is scaling up.
The Kingdom is now home to over 500 packaging manufacturing units spanning flexible packaging, corrugated boxes, rigid plastics, and metal containers. Industry leaders like NAPCO National, Obeikan Investment Group, and Middle East Paper Company (MEPCO) are heavily investing in automation, advanced production lines, and sustainability-focused innovations.
Notably, the packaging sector supports over 20 downstream industries, reinforcing its strategic role in
industrial resilience and food security. It also provides significant employment, especially in manufacturing, logistics, and retail packaging.
The sector also plays a vital role in employment and economic output, reinforcing its classification as a strategic industry under the National Industrial Development and Logistics Program (NIDLP).
SEGMENT INSIGHTS: BALANCING PERFORMANCE AND SUSTAINABILITY
Plastic Packaging
Plastic packaging continues to dominate the Saudi market despite increasing scrutiny over its environmental impact. Valued at US$12.35 billion in 2022 and growing at 6.6% CAGR, the segment thrives due to its unmatched cost-efficiency, barrier properties, and adaptability to diverse applications—from industrial bulk containers to fast-moving consumer goods (FMCG) packaging.
Key sectors such as oil and gas, construction, chemicals, and food and beverage rely heavily on plastics for protective, durable, and lightweight solutions. Polyethylene (PE), polypropylene (PP), and polyethylene terephthalate (PET) are widely used for flexible and rigid formats.
However, Saudi Arabia is also witnessing a strategic
pivot as bioplastics and circular polymers enter the mainstream. Petrochemical giants like SABIC invest in certified renewable polyolefins, while packaging firms explore recyclable multilayer films and mono-material solutions that comply with evolving regulatory norms and consumer expectations.
The dual imperative of industrial performance and environmental compliance is catalyzing innovation— positioning plastic not for elimination but for transformation.
Paper and paperboard packaging
Paper and paperboard packaging is reentering Saudi Arabia, spurred by heightened environmental consciousness, government mandates, and a growing middle class that values sustainable consumption. This segment benefits from policy momentum—such as reduced subsidies for virgin plastics— and technological innovation, as seen in the deployment of coated boards, moulded fibre, and laminated paper alternatives that offer improved barrier and structural performance.
Leading players like Obeikan and Gulf Carton are at the forefront of this transformation. Beyond producing recycled and FSC-certified boards, they invest in smart packaging technologies, including QR codes for traceability, near-field communication (NFC), and tamper-evident sealing. These innovations are critical for high-value, compliance-sensitive pharmaceuticals, electronics, and luxury personal care sectors.
As consumers and regulators increasingly demand plastic-free, recyclable solutions, paper is transitioning from a low-tech alternative to a high-performance, dataenabled material in the Kingdom’s sustainable packaging matrix.
Foodservice disposable packaging
Saudi Arabia’s food service disposable packaging segment—estimated at US$1.83 billion in 2024—is rapidly expanding in tandem with changing consumer lifestyles, the boom in food delivery platforms, and the growth of the HoReCa (hotels, restaurants, cafes) sector.
Urbanization, a youthful demographic, and postpandemic habits have spurred demand for takeawayready, microwaveable, and spill-proof packaging formats. Consequently, the segment is moving away from conventional foamed plastics and shifting toward compostable bioplastics, bagasse containers, and heatresistant moulded fibre.
Quick-service restaurant chains, particularly international franchises operating under Saudi master franchisees, are under increasing pressure to comply with global sustainability commitments. As a result, procurement decisions are guided by life-cycle
assessments, recyclability, and compostability certifications, often aligned with LEED, BREEAM, or local GSO (GCC Standardization Organization) sustainability frameworks.
This segment also attracts innovation from Saudi startups and university-industry collaborations, which experiment with date palm fibre, starch blends, and algaebased polymers—signalling a unique regional approach to sustainable disposables.
LEADING PLAYERS: DRIVING INNOVATION AND CAPACITY EXPANSION
MEPCO (Middle East Paper Company)
As one of the Kingdom’s most prominent containerboard and specialty paper producers, MEPCO exemplifies Saudi Arabia’s industrial shift toward sustainable capacity building. Its SAR 1.7 billion (US$453.25m) investment in new production lines aims to meet rising domestic demand and strengthen regional export capabilities, particularly within the GCC and North Africa.
What sets MEPCO apart is its vertical integration strategy. Through its subsidiary WASCO (Waste Collection and Recycling Co.), MEPCO sources recycled fibre locally, reducing reliance on virgin pulp and significantly lowering its carbon footprint. This closed-loop model supports Saudi Arabia’s circular economy agenda under Vision 2030 and positions MEPCO as a benchmark for responsible manufacturing in the paper sector.
Hotpack Global
While headquartered in the UAE, Hotpack Global has quickly become a formidable player in Saudi Arabia’s packaging sector. Its SAR 1 billion (US$266.62m) greenfield investment
THE DUAL IMPERATIVE OF INDUSTRIAL PERFORMANCE AND ENVIRONMENTAL COMPLIANCE IS CATALYZING INNOVATION—POSITIONING PLASTIC NOT FOR ELIMINATION BUT FOR TRANSFORMATION.
in the Kingdom highlights a dual opportunity: capturing the growing demand for foodservice disposables and aligning with Riyadh’s push for import substitution and local value creation.
The facility, which focuses on environmentally responsible packaging, is designed to cater to the evolving needs of the Kingdom’s HoReCa and retail sectors, offering microwaveable, compostable, and biodegradable formats. Hotpack’s entry also signals increasing Gulf regional integration, as it establishes a competitive base for cross-border exports and responds to pan-GCC sustainability mandates.
Obeikan Investment Group
Obeikan stands out as a technology-first packaging conglomerate, leveraging its decades of expertise in education and industrial solutions to lead Saudi Arabia’s transformation in paper packaging. The company’s investments in automation, ERP-integrated production systems, and AI-driven demand forecasting demonstrate how traditional packaging can evolve into a high-tech, efficiency-driven enterprise.
In line with Vision 2030’s digital economy aspirations,
Obeikan is deploying smart packaging features, including traceability, authentication, and consumer engagement tools like QR codes. Its diversified portfolio, covering beverage cartons, folding boxes, and high-barrier laminates, serves critical sectors such as pharmaceuticals, dairy, and electronics, reflecting a strategy rooted in value-addition and complianceintensive segments.
Gulf Carton Factory Company
Gulf Carton Factory Company has carved out a corrugated and folding carton manufacturing stronghold, balancing cost competitiveness with environmental performance. The company emphasizes lightweighting technologies, aiming to reduce raw material usage without compromising strength or functionality—an essential trait for e-commerce and industrial logistics packaging.
Gulf Carton's regional export strategy, facilitated by well-established GCC trade corridors, positions It as a vital contributor to Saudi Arabia’s non-oil export diversification. With investments in automated converting lines and recycled fluting, the firm is aligning its operations with global quality benchmarks and regional sustainability frameworks, further enhancing its competitiveness.
STRATEGIC INVESTMENTS: PUBLIC-PRIVATE SYNERGY IN ACTION
Saudi Arabia’s packaging industry is entering a pivotal phase, propelled by an unprecedented alignment between public policy and private sector ambition. These investments are expanding production capacity and steering the sector toward technological advancement, localization, and sustainability.
The Public Investment Fund’s (PIF) strategic stake in MEPCO is emblematic of a broader industrial policy shift.
It reflects a deliberate move to anchor packaging within the Kingdom’s industrial diversification roadmap, enabling the development of localized, circular material loops through investments in recycling, waste management, and low-carbon manufacturing. PIF’s backing also boosts investor confidence, positioning packaging as a future-facing sector aligned with Vision 2030.
As exemplified by Hotpack Global’s greenfield investment, private sector expansion signals growing confidence in the market’s scale, stability, and regulatory maturity. Global players are no longer entering Saudi Arabia solely as distributors or importers—they’re setting up production hubs, leveraging government incentives and tapping into the Kingdom’s growing consumer base, especially in urban centers like Riyadh, Jeddah, and Dammam.
Sector-specific funding mechanisms are creating fertile ground for innovation. Institutions such as the National Industrial Development Center (NIDC) and the Saudi Industrial Development Fund (SIDF) offer tailored
financing, R&D grants, and land access for facilities focused on biodegradable materials, circular packaging design, and automation. This empowers SMEs and startups to contribute meaningfully to the national sustainability agenda—an important step toward a diversified, innovation-led industrial base.
Together, these public-private investments are accelerating infrastructure development, technological modernization, and workforce upskilling, making the packaging sector a high-impact node in Saudi Arabia’s broader economic transformation.
Saudi Arabia’s evolving regulatory environment shapes the packaging industry’s trajectory. The government is proactively balancing economic growth with environmental stewardship, translating Vision 2030’s sustainability commitments into tangible policy actions:
The introduction of plastic bans and mandatory material labeling in 2024 marks a turning point. These measures target single-use plastics and non-recyclable materials, promoting alternatives like biodegradable polymers, paperboard composites, and compostable food service containers. Public awareness campaigns and strengthened enforcement through bodies such as the Saudi Standards, Metrology, and Quality Organization (SASO) are enhancing the success of these policies.
Extended Producer Responsibility (EPR) frameworks, currently in the pipeline, are expected to revolutionize waste management. By assigning end-of-life accountability to producers, EPR will incentivize the adoption of eco-design principles, modular packaging, and reverse logistics. It will also stimulate the growth of third-party recovery and recycling enterprises, creating new green jobs across the value chain.
The development of industrial-scale recycling infrastructure
is gaining momentum. Clusters of manufacturers within industrial cities like Jubail and Yanbu are piloting shared material recovery facilities, streamlining the collection and processing of post-consumer waste. MEPCO’s integration with WASCO is a replicable model, offering closed-loop fibre recovery that reduces reliance on imported raw materials and supports the Kingdom’s vision for resource circularity.
These regulatory shifts are not just reactive—they are preemptive enablers of competitiveness, preparing Saudi firms to meet rising sustainability standards in international markets.
FUTURE OUTLOOK: A SECTOR POISED FOR GLOBAL COMPETITIVENESS
As Saudi Arabia advances toward its Vision 2030 goals, the packaging industry is evolving into a strategic engine for economic diversification, trade expansion, and environmental leadership. Several trends are expected to shape the sector’s global competitiveness over the next decade:
Digitally enabled packaging will become the new standard. Smart labels, embedded sensors, and blockchain-powered traceability will enhance supply chain transparency, enabling real-time tracking, anti-counterfeiting, and consumer interaction. This is especially critical for pharmaceuticals, food exports, and high-value electronics, where trust and compliance are paramount.
The Kingdom is positioning itself as a regional leader in sustainable packaging, developing green standards that can be adopted across the Middle East, Africa, and Southeast Asia. With its growing manufacturing base and strategic location, Saudi Arabia is poised to export products and best practices, influencing packaging norms in emerging markets.
A concerted push toward localization of input materials, such as recycled paper, starch-based bioplastics, and plantbased resins, will reduce import dependency and strengthen industrial sovereignty. Investments in material science R&D, including university-led innovation hubs, will be crucial in unlocking new sources of bio-based packaging and alternative substrates.
The intersection of AI, robotics, and smart logistics is likely to transform production and distribution models. Automated packaging lines, predictive inventory systems, and data-driven customization will improve efficiency and reduce waste—creating an agile and responsive industry attuned to global trends.
In essence, Saudi Arabia’s packaging sector is not just growing in volume—it is transforming in value, vision, and versatility. As the Kingdom accelerates toward its 2030 targets, packaging will serve as a symbol and a vehicle for the broader industrial renaissance taking root across the nation. SPMEA
THE CIRCULAR ECONOMY
An Age-Old Concept in a Modern World
BY CYNTHIA WAINAINA, PROGRAMS ASSISTANT OFFICER - KEPRO
In today’s world, the circular economy is more than just a buzzword; it is a necessity. Businesses, governments, and environmental advocates emphasize the importance of a closedloop system where waste is repurposed into valuable resources. With a global population set to reach 9.7 billion by 2050, the planet's resources are under increasing pressure - embracing circularity is no longer optional.
However, while the term "circular economy" is gaining traction, the concept itself is far from new. In fact, some of the most sustainable and resourceful practices have existed for centuries, often within communities that never labeled them as such.
REDISCOVERING THE PAST TO SHAPE THE FUTURE
Long before the term "circular economy" gained currency in boardrooms and policy briefs, it was practised in everyday life. In rural Africa, wornout clothing is stitched, reused, or turned into cleaning rags; food scraps are fed to animals; containers are repurposed for storage; and broken items are repaired rather than replaced. These practices are born of thrift and resourcefulness but also align closely with modern sustainability goals.
Consider a group of children playing football in a dusty field. The pitch is uneven, with makeshift goalposts assembled from discarded wood. A real soccer ball is a luxury beyond their reach, so they craft one using plastic waste, bound tightly with rope. This is not merely play; it is a manifestation of the circular economy at the grassroots. Such ingenuity is echoed in urban slums like Kibera, Nairobi, where youth groups collect plastic and metal waste for resale and recycling— sometimes transforming it into furniture or art.
Globally, archaeological evidence shows that ancient communities were no strangers to recycling. As far back as 3,000 years ago, artisans in what is now the United Arab Emirates repurposed broken ceramic and metal tools into functional items. The motivation was simple: materials were precious, and nothing could be wasted.
THE SHIFT TOWARD CONVENIENCE AND WASTE
For most of human history, materials were reused and repurposed out of necessity. Single-use products, a staple of the modern era, are a relatively new concept that emerged with industrialization and mass production. Convenience became the ultimate goal, often at the expense of sustainability.
Take, for instance, the case of baby diapers. In previous generations, cloth napkins were the norm. Parents would wash and reuse them, following a well-established routine: soak, drain, rinse, wash, dry. It was an effective and accepted practice, requiring no disposable alternatives.
In sub-Saharan Africa today, disposable diapers are seen as symbols of modern parenting. But the cost—both financial and environmental—is staggering. A single child may use over 6,000 disposable diapers before being toilettrained, translating to up to one tonne of waste per child.
Similarly, in menstrual hygiene, reusable cloth pads and menstrual cups were historically common but fell out of favour due to the rise of branded, disposable sanitary products. Today, the United Nations estimates that one billion disposable menstrual products are discarded monthly worldwide, many ending up in landfills and oceans. In Africa, where affordability and waste management are critical issues, there's a growing movement to reintroduce sustainable menstrual products.
CIRCULAR ECONOMY IN AFRICA
Africa stands at a unique crossroads. As one of the world’s fastest-growing regions—with the population expected to double to 2.5 billion by 2050—the continent faces immense challenges: urbanization, youth unemployment, waste pollution, and resource scarcity. But it also has enormous potential to lead a circular transformation.
According to the African Circular Economy Alliance (ACEA), embracing circularity could unlock US$8 billion in economic value annually by 2030 in just five sectors: agriculture, mobility, built environment, electronics, and textile waste. In agriculture alone, circular approaches— such as composting organic waste or using agricultural byproducts for animal feed—can boost yields and reduce input costs.
Countries like Rwanda and Nigeria are already demonstrating what’s possible. Rwanda has banned singleuse plastic bags since 2008 and is now pioneering e-waste recycling initiatives. In Nigeria, tech startups are tackling the growing problem of electronic waste by refurbishing used electronics for resale, thereby extending their life and reducing imports.
Kenya has also made significant strides. The Extended Producer Responsibility (EPR) regulations, introduced in
2021, require manufacturers to take responsibility for the lifecycle of their products, particularly plastic packaging. Through the Kenya Plastic Action Plan, the country aims to increase plastic recycling from less than 10% to 30% by 2030.
In South Africa, the Circular Economy Roadmap (2023–2027) is expected to reduce municipal solid waste by 40% while creating over 100,000 green jobs in recycling, refurbishing, and renewable energy.
Beyond environmental benefits, circular systems have the power to create livelihoods. According to the International Labour Organization (ILO), a global shift to circularity could generate 78 million jobs by 2030. This is a powerful incentive in Africa, where 70% of youth are either unemployed or underemployed.
Even if unrecognised, waste pickers, informal recyclers, artisans, and repair technicians are already part of the circular economy. Formalizing these roles can improve earnings, enhance dignity, and drive broader economic participation.
Take the case of Gjenge Makers, a Kenyan startup that turns discarded plastic into durable paving bricks. The company reduces landfill waste and provides employment opportunities, especially for women and youth. Agbogbloshie, once known as the world’s largest e-waste dump in Ghana, is slowly becoming a hub for safe electronics disassembly and metal recovery.
LESSONS FROM THE PAST: RETHINKING OUR PERSPECTIVE
The irony is that the circular economy has always existed; it is human perception that has changed. While our ancestors reused and repurposed materials out of necessity, today’s society often prioritizes cost and convenience over sustainability. The challenge is not in creating new circular systems but in changing mindsets to embrace what has already been proven to work.
Communities that naturally adopt circular practices, whether by making toys from discarded materials, repurposing old textiles, or conserving resources, offer valuable lessons. Their approach is not driven by environmental activism but by practicality and efficiency. Yet, as the world faces mounting waste crises, climate change, and resource depletion, it is time for developed societies to relearn these age-old habits and reframe them as a deliberate and necessary strategy for the future.
Ultimately, the circular economy is not an innovation but a return to wisdom. The biggest barrier to circularity may not be technology, but mindset. If we can shift our perspective and revalue resourcefulness, we can build a future where sustainability is second nature, just as it once was
Blister packaging has become a cornerstone of modern pharmaceutical packaging due to its versatility, protection capabilities, and cost-effectiveness. Among the materials used in blister pack manufacturing, polyvinyl chloride (PVC) remains the dominant substrate thanks to its excellent thermoforming properties, clarity, and affordability. As of 2024, according to Global Market Insights, PVC accounts for over 60% of the global pharmaceutical blister packaging material market, driven by its widespread availability and compatibility with existing packaging infrastructure.
Despite growing environmental scrutiny, PVC continues to evolve through material innovations and remains aligned with global regulatory and sustainability standards. According to a recent market analysis by Research and Markets, the global pharmaceutical blister packaging market is projected to reach US$13.1 billion by 2028, growing at a CAGR of 6.7% from 2023. Much of this growth will be driven by demand for cost-effective, protective, and smart packaging in emerging economies, with PVC maintaining a central role due to its adaptability. Regions such as Asia-Pacific and Latin America are expected to lead this demand surge, where infrastructure for recycling and sustainability is being developed alongside a need for accessible pharmaceutical solutions. This trend positions PVC as a practical and strategic choice in blister packaging, especially as recyclable and barrier-enhanced variants continue to emerge.
Polyvinyl Chloride’s (PVC) resilience in PHARMACEUTICAL BLISTER PACKAGING
WHY PVC REMAINS POPULAR IN BLISTER PACKAGING
Cost-effectiveness and manufacturing efficiency
PVC is one of the most affordable and readily available plastic polymers, a key factor in its widespread adoption in high-volume pharmaceutical manufacturing. Compared to alternatives like cold-form aluminum (Alu-Alu) and cyclic olefin polymers (COP), PVC offers a significant cost advantage—it is often 30–50% cheaper in material costs and requires lower energy input for thermoforming.
This affordability is further amplified by its superior thermoformability, which efficiently produces precise and uniform blister cavities with minimal thermal energy. Blister production using PVC supports highly consistent form-fill-seal cycles, minimizes material waste, and reduces tooling and maintenance expenses.
In contrast, while offering excellent barrier properties, cold-form foil systems involve higher capital expenditure due to slower forming speeds and more complex tooling requirements. Similarly, COP and COC materials, although gaining traction for premium or biologic drug formats, remain cost-prohibitive for most generic and high-volume applications.
Due to these efficiency gains, companies such as Gerresheimer and Huhtamaki built high-output blister lines around PVC. Gerresheimer’s facilities in India and Europe use PVC blister films optimized for rapid
GERRESHEIMER’S FACILITIES IN INDIA AND EUROPE USE PVC BLISTER FILMS OPTIMIZED FOR RAPID THERMOFORMING, DELIVERING OVER A MILLION BLISTERS DAILY FOR GENERIC AND BRANDED DRUG MANUFACTURERS.
thermoforming, delivering over a million blisters daily for generic and branded drug manufacturers. Huhtamaki, through its flexible packaging division, has developed modular blister platforms compatible with rotary and platen sealing technologies, allowing seamless transitions between PVC and recyclable PVCbased films.
Furthermore, equipment manufacturers like Uhlmann and IMA have designed new machinery compatible with PVC film, including micro-adjustment features to accommodate thinner PVC films and reduce material usage. These integrations highlight the industry's commitment to maintaining PVC's role while improving resource efficiency and sustainability.
Transparency and drug visibility
PVC's clarity is a critical asset in pharmaceutical packaging. It offers high transparency that enhances product visibility. This allows pharmacists and patients to verify the integrity, colour, and count of tablets or capsules visually without opening the packaging, which is essential for patient confidence and correct medication usage.
In retail settings, this transparency aids in fast identification and reduces the risk of dispensing errors. Furthermore, in regulated markets, clear visibility of the drug product enables seamless quality control and visual inspection procedures, ensuring compliance with stringent safety and traceability standards.
The importance of this visual access becomes even more pronounced in low-literacy regions, where colour or shape recognition is often relied upon for proper medication use, reinforcing both adherence and patient safety.
Adaptable barrier properties
While uncoated PVC has limited barrier performance, it can be significantly enhanced with functional barrier layers tailored to pharmaceutical needs. Laminates such as PVC/PVDC, PVC/PE/PCTFE, and PVC/ Aclar® are widely used in applications where moisture, oxygen, or light sensitivity is a concern. These advanced combinations enable drug manufacturers to precisely match barrier protection to each product's shelf-life requirements and environmental exposure profiles.
For example, PVC/PVDC is often chosen for its excellent moisture and gas barrier properties in tropical climates. At the same time, PVC/ Aclar® is favoured for premium drugs due to its ultra-low moisture vapour transmission rates and clarity.
Industry leaders like Perlen Packaging and Honeywell have developed customized highbarrier laminates that optimize thickness, sealing performance, and machinability, catering to regional and global markets. These barrierenhanced laminates allow pharmaceutical companies to expand their distribution footprint without compromising drug efficacy or compliance with stringent packaging regulations.
LATEST INNOVATIONS AND ENHANCEMENTS IN PVC-BASED BLISTER PACKAGING
Recyclability-enhanced PVC films
Environmental regulations in the EU and other developed markets are increasing pressure on the pharmaceutical sector to transition toward recyclable and circular packaging solutions. In response, manufacturers like Klockner Pentaplast have developed recyclable PVC-based films such as kpNext™, which meet recyclability standards set by CEFLEX and RecyClass.
These films are engineered to be collected, sorted, and processed within existing PVC recycling infrastructures, allowing them to align with extended producer responsibility (EPR) schemes and regulatory mandates.
Similarly, Bilcare Research has developed recyclable PVC blister solutions that use eco-design principles to reduce environmental impact without compromising performance.
For manufacturers, the benefits go beyond compliance. By adopting recyclable PVC solutions, companies enhance their brand reputation, reduce potential penalties associated with non-compliance, and future-proof their operations in anticipation of more stringent regulations. In addition, recyclable PVC films can support eligibility for eco-labels and procurement programs increasingly favoured by healthcare providers and institutional buyers.
Low-PVDC or PVDC-free barrier alternatives
PVDC, though long valued for its excellent moisture and gas barrier properties in blister packaging, presents significant
environmental and disposal challenges due to its chlorine content, which can release harmful compounds such as hydrochloric acid and dioxins during incineration.
This raises regulatory and public health concerns, particularly in regions with strict environmental legislation. In response, the pharmaceutical packaging industry is actively exploring and commercializing next-generation barrier materials that match or exceed PVDC’s performance without the associated environmental drawbacks.
These alternatives aim to retain critical functionalities such as sealability, machinability, and shelf-life protection while offering improved end-of-life recyclability, lower carbon footprint, and compliance with emerging global sustainability mandates. Emerging alternatives include:
• PERLALUX®-Ultra Protect by Perlen Packaging:
Utilizes a proprietary high-barrier coating that delivers robust protection against moisture while minimizing the environmental footprint associated with conventional PVDC-based films. Unlike traditional PVDC, which poses challenges during incineration and end-of-life disposal, PERLALUX®-Ultra Protect features a chlorinefree formulation that meets regulatory and sustainability expectations in Europe and North America. This innovation enables pharmaceutical companies to maintain the same sealing, machinability, and barrier performance while improving recyclability and reducing toxic emissions. As a result, manufacturers benefit from lower compliance risks, improved lifecycle assessments, and greater acceptance in environmentally conscious markets.
• Liveo™ Pharma Coated Films by DuPont: These films use non-PVDC barrier coatings that provide moisture and oxygen protection comparable to traditional PVDC laminates while significantly improving environmental outcomes.
The non-chlorinated barrier technology minimizes the release of harmful compounds during incineration and complies with strict European disposal regulations. DuPont has engineered these films to retain compatibility with existing blister packaging lines, making the transition seamless for pharmaceutical manufacturers.
By adopting Liveo™ films, companies can meet their product protection and sustainability targets, benefit from reduced regulatory risk, and appeal to environmentally conscious stakeholders without compromising performance.
INTELLIGENT AND CONNECTED BLISTER SOLUTIONS
Integrating smart technologies into blister packs is becoming a priority. Amcor’s Smart Blister platform is one such innovation, embedding printed electronics and sensors into existing PVC/PVDC structures. These smart packs can track patient adherence, verify product authenticity, and transmit usage data—essential for digital healthcare models. Importantly, they work with standard blister tooling, reducing implementation friction.
REGULATORY COMPLIANCE AND SAFETY ASPECTS
PVC used in pharmaceutical packaging must comply with pharmacopeial standards such as USP <661.1>, EP 3.1.11, and JP 7.03. USP <661.1> (United States Pharmacopeia) outlines the physicochemical testing requirements for plastic materials used in pharmaceutical packaging. It assesses parameters such as identity, extractables, and physicochemical properties to ensure the material does not adversely affect the drug product. Meanwhile, EP 3.1.11 (European Pharmacopoeia) specifies the quality and safety requirements for non-plasticized PVC used in containers for pharmaceutical preparations. It includes testing for transparency, colour, mechanical properties, and extractable substances to prevent drug interactions or contamination.
JP 7.03 (Japanese Pharmacopoeia) focuses on testing for heavy metals, extractables, and other potentially harmful substances. Compliance ensures that the PVC material meets Japan's pharmaceutical market's purity and inertness standards.
These standards ensure that materials in direct contact with drugs are nontoxic, nonreactive, and do not leach harmful substances. Innovative PVC suppliers are now offering pharma-grade, low-extractable formulations to meet regulatory expectations for high-purity applications further. Additionally, efforts are underway to harmonize recyclability with GMP standards, paving the way for compliant and sustainable PVC packaging
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