Q&A: The case for corrugated

Sustainability has become a key driver in the food and consumer packaged goods sectors, with 70% of consumers prioritizing eco-friendly and ethically produced products, according to NielsenIQ’s “Global State of Health Wellness 2025” report. Additionally, 71% of consumers are willing to pay a premium for sustainable and ethical products sourced through a sustainable supply chain, highlighting a significant shift toward intentional spending amidst rising food prices and environmental concerns.

In response, retailers are stepping up their sustainability initiatives, according to FMI – The Food Industry Association’s The Food Retailing Industry Speaks 2025 report:

68% of retailers have energy reduction targets
54% are focused on reducing packaging waste
53% are addressing their carbon footprint (32% with plans in place and 21% in progress)

Recently, the Corrugated Packaging Alliance released a life cycle assessment to provide science-based data on the environmental impact of corrugated packaging. The study shows corrugated packaging outperforms reusable plastic containers in four of eight environmental categories, including greenhouse gas emissions and nonrenewable energy use. The study is particularly timely as retailers and supply chain leaders seek concrete data to inform sustainability discussions, moving beyond broad commitments to data-driven decision-making.

“Instead of asking whether corrugated is sustainable, companies can look at eight distinct environmental categories and make decisions based on their commodity, their supply chain, and their reporting requirements,” said Cory Martin, executive vice president of Itasca, Ill.-based nonprofit trade group Fibre Box Association.

Here, Martin breaks down how corrugated’s advantages are especially relevant as companies assess packaging choices that align with both climate action and efficiency priorities.

What was the motivation behind the new Corrugated Packaging Alliance’s life-cycle assessment research, and why is it especially relevant for the industry right now?

The industry needed credible, science-based data to back up its environmental claims. A life cycle assessment (LCA) is a globally recognized scientific method for measuring environmental impacts throughout a product’s entire life. It examines everything from raw material extraction and manufacturing to transportation, use and end-of-life disposal or recycling. The research is relevant now because retailers continue to cite sustainability priorities along with cost effectiveness as top areas for improvement in the supply chain. This study gives the corrugated industry concrete, credible numbers to bring to those conversations.

Sustainability is increasingly important in the food and beverage industry. What major sustainability pressures are food and consumer goods companies facing today, and how does this new study help leaders make more informed packaging decisions?

Retailers continue to look for sustainability and efficiency along their supply chains, particularly around greenhouse gas emissions. The value of this study is that it moves the conversation from general commitments to specific data. That level of detail is what leaders actually need.

The report highlighted eight environmental impact categories. Where does corrugated packaging show the most meaningful environmental advantages, and why do those differences matter in real-world operations?

Corrugated outperformed reusable plastic containers in four of eight categories, with 57 to 110 percent better performance on greenhouse gas emissions, respiratory health effects and non-renewable energy use. For example, local sourcing and shorter supply chains give corrugated packaging a clear edge in reducing emissions and costs throughout the distribution process.

How does the recovery rate of corrugated packaging influence its overall life-cycle performance, and what should supply chain leaders take away from that?

Corrugated is recycled at a rate of 69 to 74 percent. Polypropylene plastic containers come in at 8 percent. That gap has a real impact on cradle-to-grave environmental calculations. For supply chain leaders, the practical takeaway is that a packaging system that reliably re-enters the material stream is one that supports circular economy goals, not just in messaging, but in the numbers.

Logistics leaders spend a lot of time on packaging weight. How does corrugated’s lighter weight translate into measurable environmental and operational benefits?

Reusable plastic containers can weigh up to four times more than corrugated, and that compounds fast. More weight per unit means more trucks on the road and higher emissions per delivery. RPCs also struggle to maximize cargo space the way corrugated can. The weight advantage is not just an environmental win. It shows up directly in freight costs.

The research found trade-offs between corrugated and reusable plastic containers. How should leaders think about those trade-offs?

Neither system wins across the board, and the research is honest about that. The key is evaluating by commodity, transport distance and operational context rather than picking one system for everything. Where corrugated holds a clear edge is in the categories that matter most right now, including climate, energy and respiratory impact.

Looking ahead, where is there still room to improve, and how is Fibre Box working with members to drive progress?

The industry has already made real gains, as shown in our 2023 LCA, including meaningful reductions in energy usage, water usage, acid rain and smog. Our progress was achieved through energy efficiency improvements, strong recycling infrastructure, sustainably managed forests and an ongoing commitment to continuous improvement. The industry continues to shift to cleaner-burning fuels, has increased its participation in a greener US electric grid and has made investments in energy efficiency. But there is still work to do on water use, ozone depletion and eutrophication. The goal is to give members a shared, science-based foundation they can use to set targets, talk to customers and keep improving.