Rethinking packaging through circular packaging design

As environmental regulations tighten and consumer expectations evolve, businesses across sectors are re-evaluating how their packaging choices impact sustainability. In this shift, circular packaging emerges not as a trend, but as a long-term solution one that balances environmental responsibility with operational performance. At Solidus, circularity is not an added feature. It’s embedded into every fibre of our product development, manufacturing and supply chain.

Why circular packaging matters

Traditional packaging systems follow a linear model: take, make, discard. This approach is resource-intensive and contributes significantly to global waste, particularly in industries reliant on single-use plastics and multi-material formats. Circular packaging replaces this model with one designed for reuse, recycling and material recovery.

The circular approach reduces dependency on virgin materials, lowers carbon emissions and helps businesses meet environmental compliance targets. It also opens new opportunities for innovation and cost efficiency, especially when paper-based materials are used strategically.

Built for circularity

Solidus packaging solutions are developed with the full product lifecycle in mind. Our solid board is made from over 90% recycled fibres and is fully recyclable within existing European waste systems. Unlike composite or plastic-based materials, our packaging is mono-material, making sorting and recycling straightforward and effective.

But circularity goes beyond material choice. It involves smart design, manufacturing efficiency and logistics integration. Our paper-based packaging is optimised to reduce excess weight and volume, which helps lower emissions across the supply chain. In many cases, our solutions replace plastic trays, sleeves or liners entirely — without compromising performance.

Working closely with our customers, we design packaging that meets strict requirements for strength, hygiene and shelf appeal, while maintaining a minimal environmental footprint. This makes our approach ideal for industries such as chilled and frozen food, horticulture, pharmaceuticals and consumer goods.

Supporting sustainable supply chains

True circularity extends through the entire supply chain. That’s why Solidus operates a vertically integrated production model. From sourcing recovered paper to manufacturing board and converting it into final packaging, we maintain full control over every stage. This ensures consistency, traceability and sustainability.

In practice, this means fewer transport steps, more efficient material flows and reduced dependency on external suppliers. For our customers, it translates into reliable delivery, consistent quality and measurable environmental impact reduction.

Moreover, our board products can be customised to support specific circular ambitions such as reducing material use per unit, improving recyclability rates or meeting sector-specific environmental certifications.

Solidus continuously invests in modernising its facilities, using renewable energy and optimising water usage in production. These improvements are reflected in our sustainability reports and verified by third-party certifications.

Innovation through collaboration

Circular packaging is not one-size-fits-all. Every business faces unique challenges related to product dimensions, shelf life, branding and distribution. Our role is to provide tailored solutions that align with these needs, while enabling progress towards circular goals.

To do this, we offer in-house design, prototyping and performance testing through our Solidus Experience Centers. Here, customers work directly with our engineers to refine packaging that balances strength, protection and environmental impact. We also support machine integration and logistics optimisation to ensure that circular solutions work seamlessly with existing processes.

The success of these collaborations is visible across many sectors. For example, one of our customers in the fresh produce industry replaced plastic trays with fibre-based alternatives, resulting in a 75% reduction in CO₂ emissions while maintaining full product integrity.

Branding and communication

Sustainable packaging is not only a technical decision. It’s a powerful tool for brand positioning. Consumers increasingly prefer products that reflect their environmental values, and packaging is often the first physical interaction with a brand.

Our packaging solutions combine circularity with premium print capabilities, helping businesses communicate their commitment to sustainability without compromising design. Whether it’s food-grade paper-based packaging with direct print or luxury finishes for consumer products, we make sustainability visible and tangible.

A circular future starts now

Companies are under increasing pressure to reduce waste, cut emissions and embrace sustainable innovation. Circular packaging offers a strategic pathway forward — one that is measurable, credible and aligned with both regulatory frameworks and customer expectations.

By choosing fibre-based, recyclable materials and partnering with a supplier that understands the full scope of circularity, businesses can make packaging a driver of positive change. At Solidus, we help our customers move beyond linear thinking and towards truly sustainable packaging systems. From concept to implementation, our focus remains on durability, efficiency and environmental integrity.