Aquapak, the speciality polymers business, has today launched its ‘Reality of Fashion’ report, which provides a progress update on Fashion for Good’s “Polybags in the fashion industry: evaluating the options” which was published two years ago. Its new research also shows consumer desire for more environmentally friendly mailer bags when purchasing fashion items.

Aquapak’s report highlights that despite increasing pressure for alternative packaging solutions to single-use plastic as part of a green revolution, progress since 2019 has been slow. The majority of garment and accessory bags are still made from Low Density Polyethylene (LPDE), with billions used every year, and recycling rate remaining stubbornly low. Just 29% of recycling capacity across Europe can recycle LDPE with 15% of this in Germany, 14% in Italy and 13% Spain*.  According to The UK Plastics Pact, in the UK, just 6% of all flexible plastic packaging is recycled, this includes Polypropylene, PET and LDPE.

Aquapak has also conducted new research with UK consumers which supports the need to move away from single-use plastics for fashion items such as clothes, sunglasses and accessories. Over half (52%) said that poor packaging recyclability puts them off buying items online or by mail order altogether.  It also highlights consumers’ concerns about the environmental harm caused by plastic, with 58% of consumers said it is plastic breaking down to microplastics in the ocean and harming wildlife which concerned them most. This was followed by plastics going to landfill (24%) and being incinerated and causing more pollution (12%).  All points raised in the original Fashion for Good report.

Despite the slow shift towards more sustainable forms of packaging, innovation has delivered solutions which are now readily available, including starch based compostables and new-generation plastics such as Hydropol, a new speciality material that is an enabling technology for the circular economy based on PVA.  Hydropol enables paper-based packaging to be produced with all of the functionality of LDPE, but is fully recyclable and biodegradable without producing harmful microplastics which are so damaging to the environment.  The technology is already gaining interest in the food service sector, with the award-winning Flexi-Kraft Takeaway Bag produced by Euro Packaging.

Some fashion brands such as Finisterre are embracing change and have already committed to adding to their sustainable packaging with a new innovative paper mailing bag concept, which combines enhanced end-user functionality with recyclability through its use of Hydropol.  However, more need to follow suit to have the impact consumer’s demand.

Mark Lapping, CEO of Aquapak, said: “The reality is that there are a range of packaging alternatives available which offer more favourable end-of-life options in terms of recycling and biodegradability.

Although materials made with Hydropol are fully recyclable – indeed, in combination with paper, it actually enhances the recovery of paper fibres in the recycling process – we still have to work with the existing recycling infrastructure which has yet to fully adjust to the circular economy.  

“The more brands collaborate and adopt new packaging technologies such as Hydropol, increasing the volume of PVA material, so will the viability of recycling around the world, closing the loop and making the circular economy a reality. There is a huge opportunity for fashion industry brands can make a positive impact right now by switching to the alternative packaging solutions which are already available – the more that do, the quicker the pace of change. For good.”

An overview of traditional mailing bags vs paper-lined alternatives

Whilst traditional mailing bags provide protection, being made from PE are limited in reuse and often recycling which is not always available. Paper is seen as more environmentally friendly by consumers thanks to its curbside recyclability. Compostables (assuming this option is chosen by the end user) offer lower environmental impact but reduced functionality. New-gen materials such as Hydropol when combined with paper retain the properties needed to protect items whilst giving multiple end of life options, removing the reliance on end-users to leave no trace on the environment.

Kraft lined with Hydropol is up to 20% stronger and 50% lighter than alternative paper e-commerce mailers

Aquapak has developed a novel biodegradable, non-toxic and water-soluble polymer called HydropolTM which is three times stronger than alternatives and is designed to be used in existing thermo-processing equipment, giving it a wider range of applications.  HydropolTM enables up to 100% paper/board recovery whatever the percentage packaging makeup.

The base plastic is currently used for dishwasher tablets, ingestible pill casings and soluble stitches.  HydropolTM‘s resistance to low temperature solubility and high barrier to elements adds functionality, providing a wider range of uses.  It can be recycled, re-pulped, composted and is distinctively compatible with anaerobic digestion.  Furthermore, if unintentionally released into the natural environment, HydropolTM – which is non-toxic and marine safe – will dissolve and subsequently biodegrade, leaving no trace.

Blown film products commercially available and made from HydropolTM include garment bags, ESD bags, organic waste disposal bags and laundry bags for infection control.  Its solubility makes it easy to separate from other materials, simplifying the confusing recycling options that exist for different packaging.

Extrusion coatings and laminates for paper/board applications are at customer production and trial stages, including a number of home delivery and ecommerce applications, packaging for dried pet food, snacks, cooked meat and convenience food applications.

Other applications under development with customers and development partners include nonwoven fibres for applications such as wet wipes and cellulose combinations for thermoformed trays as well as injection moulded parts such as golf tees.

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