Sustainable Packaging Without the Risk: 5 Smarter Approaches for 2026

Sustainability in packaging is an expectation in 2026. As customers, regulators and supply chains become more environmentally conscious, packaging decisions are under greater scrutiny than ever.

But at SmartShield, we see one issue come up again and again: sustainable packaging only works if it still does its job.

Damaged products, returns and remanufacturing come with a heavy environmental cost of their own. So rather than chasing trends, the smarter approach is balancing material choice, protection, logistics and lifecycle impact.

Here are five practical ways to make packaging more sustainable in 2026, without increasing risk.

1. Replace single-use plastics where performance allows

One of the most visible shifts in recent years has been the move away from plastic-based consumables.

Where protection requirements allow, many businesses are now choosing paper-based void fill such as recycled kraft, crumpled paper and newsprint in place of traditional plastic options.

Other sustainable packaging options include:

• Paper strapping as an alternative to polypropylene
• Recyclable stretch wrap options such as DK stretch wrap
• Eco bubble alternatives
• Biodegradable loose fill
• Paper-based void fill
• Cardboard mailers
• Paper tape solutions
• Green Cell Foam

All of these options can help a company reduce its plastic packaging use when matched to the right application. However, the suitability of each solution will depend on what the product will experience in transit.

2. Use foam more intelligently - not automatically

Foam packaging often gets labelled as “unsustainable,” but that view misses important nuances.

For a start, more environmentally conscious foam options are available in 2026, including:

• Polyethylene foam rolls and sheets made with recycled content
• Cornstarch-based foam sheets and packing peanuts that dissolve in water

SmartShield’s ECO Poly Foam rolls, for example, contain approximately 65% recycled content, which offers impact protection while reducing virgin material use.

In addition to this, we also need to consider how sustainability isn’t just about materials, but outcomes.

In many cases, a well-designed foam solution inside a cardboard box will dramatically reduce damage rates, which, more often than not, is way more sustainable than replacing damaged products, repackaging them, and shipping again.

3. Consider paper-based protection alternatives to foam

In some applications, foam can be replaced entirely with paper-based protection.

Options such as:

• Corrugated wrap systems (like Corrpack-style solutions)
• Honeycomb blocks or bracing
• Moulded pulp inserts

These materials can provide effective shock and vibration protection while remaining recyclable and lightweight. Honeycomb and moulded pulp, in particular, are strong alternatives to expanded polystyrene when part geometry and weight allow.

The key is matching the material to the risk profile of the product.

4. Zoom out: Packaging failures are an environmental problem too

As we’ve already touched on, one of the most overlooked sustainability issues in packaging is product damage.

When a product is damaged in transit:

• It often ends up in landfill
• A replacement must be manufactured
• New packaging is required
• Additional shipping and fuel emissions are generated

Billions of dollars of damaged products are discarded every year. In this context, the “most sustainable” packaging is the one that prevents failure in the first place, even if it includes materials like foam.

Right-sizing packaging, reducing void space, and improving protection can also lower freight volume: another environmental win.

5. Build sustainability into the full packaging lifecycle

Beyond materials, sustainability improves dramatically when packaging is designed with its full lifecycle in mind.

This looks like:

• Returnable packaging systems for repeat shipments, such as wooden crates and plastic cases
• Printing clear recycling instructions directly on packaging
• Designing foam sets that can be reused internally for part protection or material handling

Small design decisions can make a big difference to what happens after the product is unpacked.

Final thoughts: Sustainable packaging is a balancing act

There’s no universal “green” packaging solution, and anyone claiming otherwise is oversimplifying a complex challenge.

The most sustainable packaging strategy is one that:

• Protects the product properly
• Minimises waste and returns
• Uses the right materials for the right job
• Considers transport, storage and reuse

At SmartShield, sustainability isn’t about ticking boxes, it’s about designing packaging that performs responsibly, end to end. 

Sustainable packaging FAQs

Q1. Is sustainable packaging suitable for high-risk or regulated industries?

Yes, when designed correctly. In sectors such as aerospace, defence, medical, and electronics, sustainability must never compromise protection or compliance. The most effective solutions balance recycled or recyclable materials with proven protective performance.

Q2. Is foam packaging always unsustainable?

No. While some foams are less environmentally friendly, modern options with recycled content or reusable designs can significantly reduce overall environmental impact by preventing product damage and waste.

Q3. Can paper-based packaging replace foam for industrial applications?

In some cases, yes. Paper-based solutions such as honeycomb, corrugated wrap, or moulded pulp can offer excellent protection, depending on product weight, fragility, and transit conditions.

Q4. How do I know which sustainable packaging option is right for my product?

The right solution depends on your product’s risk profile, supply chain, and handling environment. Testing and packaging design expertise are essential to ensure sustainability improvements don’t increase failure rates.

Q5. Does sustainable packaging always cost more?

Not necessarily. While material costs can vary, reductions in damage, returns, freight volume, and waste often result in lower total costs over the full packaging lifecycle.

If you’re reviewing your packaging in 2026, we’re always happy to help you assess where improvements can be made - without compromising protection.