Businesses around the world are switching back to paper-based packaging to appeal to eco-conscious customers and stem the tide of plastic pollution.
The specialty coffee sector is no different. One trend that is predicted to dominate coffee packaging in 2022 is imperfect, raw materials characterised by their compostability, off-white backdrops, and earthy textures.
Packaging materials such as kraft paper fit the bill perfectly. As it is sustainable, affordable, and relatively easy to recycle, kraft paper has always been a popular food and beverage packaging material.
Additionally, kraft paper can be used in its original unbleached form. Or, it can be processed into a bleached white paper to help make branding stand out on the shelf.
When lined with another material or coated for extra protection, kraft paper packaging can prove to be a beneficial and cost-effective option for many coffee roasters.
Read on to find out which kraft paper option is best suited for your packaging needs.
Before plastic was popularised, businesses used paper bags to package products for centuries.
The first mass-produced envelope paper bag machine and flat bottomed paper bag machine were invented in the 1800s. These paved the way for the paper bags that are still commonly used today. However, the quality of paper available at the time was low.
As a result, German chemist Carl Dahl created the kraft paper manufacturing process in 1879. Made from natural wood sources, its manufacturing process involves a higher ratio of sulphur compared to conventional paper.
This helps strengthen its fibres and cellulose, making it stronger than recycled paperboard. Additionally, this is what gives the paper its name, as “kraft” means “strong” in German.
During the kraft process, manufacturers heat and pulp wood chips in a pressurised vessel. Adding caustic soda and sodium sulphide created a more flexible pulp than the traditional mechanical pulping process creates on its own.
These additions break down the wood’s lignin, which is what glues its fibres together. This creates brown fibres which are cleaned, bleached, and processed into elastic and tear-resistant brown kraft paper.
Further bleaching treatments are used to turn some of this into white kraft paper.
The main difference between bleached and unbleached kraft paper is appearance.
Unbleached kraft paper does not undergo chemical processing and remains brown in colour. When left in its unbleached form, it is completely compostable, making it an eco-friendly choice for roasters and cafe owners.
However, unbleached kraft paper has limited resistance to oil and moisture. As a result, it usually requires an additional lining or coating in order to be impermeable to these substances.
To produce uniform white paper suitable for full colour printing, manufacturers reduce the colour tint and purity of paper pulp through bleaching.
Known as delignification bleaching, the process uses oxides such as chlorine and ozone, or bleaching agents like chlorine dioxide and hydrogen peroxide to do this.
A common misconception is that the bleaching process makes the kraft paper less sustainable and may have negative effects on the environment. However, bleached kraft paper can also be compostable, depending on the chemicals used to process it.
Modern paper manufacturers now use oxygen, ozone, or hydrogen peroxide to bleach the paper. This produces fewer toxic and carcinogenic compounds that could damage the environment.
Like brown kraft paper, it will also require a lining to be completely resistant to water and oil.
Both white and brown kraft paper are suitable for packaging roasted coffee. The choice for roasters boils down to how they want their packaging to be portrayed to customers.
Roasters who have an existing and recognisable brand can opt for white kraft paper. This option will reproduce images, colours, and logos more accurately during print runs.
Alternatively, roasters who want to portray a rustic, natural feel may find that brown kraft paper is a better choice.
Additionally, roasters who opt for brown kraft paper bags can use custom printed stickers and labels as part of their branding.
Before seeking out either choice of paper packaging, roasters should consider the following factors.
Not all kraft paper comes from a sustainable or ethical source. Roasters can determine if the paper comes from a responsibly managed forest by inquiring whether it is Forest Stewardship Council (FSC) certified.
Furthermore, the mill producing the paper should be able to prove that it repurposes the majority of its black liquor – the toxic byproduct of kraft that can pollute water sources.
Many petroleum-based inks contain volatile organic compounds (VOCs). Using them on kraft paper packaging may result in it damaging the environment as it decomposes.
Roasters can choose to use sustainable water-based, soy-based, or vegetable-based inks that are low in VOCs, and work particularly well on paper substrates. Furthermore, they are fully biodegradable.
To preserve the lifespan of roasted coffee, roasters can include a lining to better protect the beans from heat, moisture, oxygen, and direct sunlight. This is particularly important when packaging large volumes of coffee.
In many cases, linings are made from traditional plastic or aluminium, which can be challenging to separate and recycled. Therefore, bioplastic linings, such as those made from polylactic acid (PLA) are a more sustainable option, as once they are separated, both materials can be recycled or composted appropriately.
Any efforts to use eco-friendly coffee packaging material will be in vain if customers aren’t aware of it and dispose of it incorrectly.
Roasters can use coffee bags to educate consumers about which recycling bin they can use. Alternatively, roasters can encourage customers to return their empty coffee bags to the roastery to ensure it is properly recycled.
Packaging manufacturers have made great strides in ensuring that both types of paper have a minimal negative impact on the environment, provided roasters choose a packaging supplier that shares their commitment to sustainability.
At MTPak Coffee, we can provide roasters with FSC-certified brown and white kraft paper packaging, complete with eco-friendly liners for added barrier protection.
In addition to UV printing methods, we use sustainable, water–based inks to ensure branding stands out to consumers while limiting environmental impact. These are low in volatile organic compounds (VOCs) and are recyclable.
We also offer recyclable BPA-free degassing values and resealable zippers to help preserve the freshness of roasted coffee, from the roastery to the consumer.
With a rise in demand for a more sustainable approach to packaging, kraft paper has made an impactful contribution to meeting these demands.
There is no doubt that kraft paper packaging solutions have gained popularity in the packaging industry, and the capabilities of this material continue to grow.
But why?
Let’s jump right into what kraft paper is and why it has gained so much popularity!
What is Kraft Paper?
Kraft comes from the German word “strong”, and kraft paper is just that!
Raw kraft is durable, tear-resistant, and brown in color thanks to the kraft pulp process.
Ideal for creating durable wrapping kraft paper and sturdy cartons and rigid boxes, kraft paper board is actually also available in a range of colors and shades making it highly versatile for branded packaging solutions.
Source: PakFactory
The surface of raw kraft paper is textured and porous allowing for high-quality printing and finishing for a premium rustic look.
The Kraft Paper Production Process
Kraft paper is a packaging material that gets its name from the Kraft pulping process, pioneered by Carl F. Dahl of Germany in the 1880s.
Normally, in the manufacturing of paper, wood is ‘pulped’ (ground to a pulp) first, but Dahl found that treating the cellulose pulp with certain chemicals (sulfates) increased the strength of the kraft paper.
Initially used as wrapping material, the durable and sturdy nature of kraft paper made it popular for producing packaging solutions like the classic brown kraft paper cardboard box we all recognize today.
Kraft vs. Regular Paper
Some people may say, “It’s just paper, what makes it so special?
Well, to put it simply, kraft paper is stronger.
Thanks to the kraft process mentioned previously, more lignin is stripped from kraft wood pulp leaving more cellulose which gives paper its tear-resistant and durable characteristics.
Raw kraft paper tends to be more porous than regular paper too, making it a little less effective for printing but extremely susceptible to special finishing processes such as:
Embossing/debossing
Foil stamping
How is Kraft Paper Used in Packaging?
Today, kraft paper is primarily used for corrugated boxes and recently has become very popular for carton boxes too!
Thanks to kraft paper’s durable nature the e-commerce industry benefits from corrugated boxes to protect products and ensure they withstand harsh shipping conditions.
Source: PakFactory
Brown kraft paper carton boxes are also commonly used by businesses to achieve sustainability goals and clearly portray eco-friendly initiatives through brown kraft paper’s rustic and raw look.
Kraft paper is very versatile and allows for a wide range of innovative packaging options in today’s packaging industry.
Types of Kraft Paper
Coated Unbleached Kraft (CUK)
This material is considered to be the most basic version.
There is no ‘bleaching’ or further addition of chemicals other than those patented by the kraft process.
For this reason, it is also called Solid Unbleached Sulfate or SUS and consists of 80% virgin fiber wood pulp/cellulose kraft pulp.
This has great tear resistance and a high degree of stiffness, all without being too thick.
In fact, it is the thinnest of all kraft paper-based packaging substrates.
It has a naturally occurring kaolin clay-titanium dioxide coating on its surfaces to improve smoothness and make printing easier.
Solid Bleached Kraft Paper (SBS)
While unbleached Kraft paper is considered more eco-friendly due to its natural color and lack of chemical processing, it may not always be the optimal choice for certain applications, such as packaging for luxury or high-end products.
In these cases, bleached Kraft paper may be preferred, as it offers a smoother surface and brighter appearance that can enhance the printing quality and provide a more premium look and feel.
However, it’s important to note that the bleaching process can have environmental impacts, and businesses should carefully consider the trade-offs between aesthetics and sustainability when choosing between bleached and unbleached Kraft paper.
Ultimately, the choice will depend on the specific needs of the business and the product being packaged, as well as their commitment to sustainability and environmental responsibility.
Coated Recycled Board (CRB)
CRB is 100% recycled kraft paper.
Because it is not made from virgin fiber, its specifications/tolerances are less than that of SBS.
However, recycled kraft paper is also a low-cost packaging substrate that is ideal for instances where high tear resistance/strength is not necessary, such as in the case of cereal boxes.
This also makes it easy for product manufacturers to pass on the cost savings to their consumers and gain a competitive advantage in the market.
The materials mentioned above refer to what we commonly see as folding cartons.
For corrugated boxes, more strength is derived by adding layers of kraft paper
This is called ‘fluting’.
Read more about corrugated packaging
The Benefits of Kraft Paper
Apart from its superior strength and protection, it is 100% eco-friendly.
It degrades naturally within a few weeks, decomposing just like leaves that fall off a tree.
It leaves no impact on the environment, but no one needs to wait that long.
Kraft paper can be recycled for use in new packaging.
Being eco-friendly and having FSC-certified recycled packaging can help increase sales of your product as the world is now realizing the importance of the environment and why it must be protected.
Customization Options for Kraft Paper
Customization options for kraft paper are vast, and they can add a personal touch to your packaging while also promoting your brand.
Many printing companies offer custom kraft paper printing options, allowing you to add your branding or design to your packaging.
This can include adding your company logo, tagline, or other artwork to your kraft paper packaging. You can also choose from a range of finishes, such as matte or gloss, to give your packaging a unique look and feel.
Additionally, you can experiment with different colors and patterns to create a packaging design that reflects your brand personality.
By customizing your kraft paper packaging, you can create a memorable unboxing experience for your customers, which can help increase brand awareness and customer loyalty.
Source: PakFactory
The Environmental Impact of Kraft Paper
The environmental impact of kraft paper is an important consideration when choosing it as a packaging material.
Kraft paper is made from wood pulp, a renewable resource, which makes it more sustainable than other packaging materials.
Additionally, kraft paper is biodegradable and can be recycled, which means it has a lower impact on the environment than plastic or Styrofoam packaging.
When considering the environmental impact of kraft paper, it is also important to consider the manufacturing process.
The kraft process involves using a mixture of chemicals to break down the wood chips, which can have negative environmental impacts if not managed properly.
However, many kraft paper manufacturers have implemented sustainable practices to minimize their environmental impact, such as using renewable energy sources and minimizing chemical waste.
Overall, kraft paper is a more environmentally friendly packaging option than many other materials available on the market today.
Sonhab Chocolate: A Quick Case Study
Sonhab Chocolate, a small-batch chocolatier, was facing a challenge to remain sustainable while creating a unified branding experience for their customers.
They wanted to ensure that their packaging aligned with their values, their commitment to sustainability, and their operational needs.
To address this issue, PakFactory recommended Kraft paper boxes as a solution.
Source: Sonhab Chocolate by PakFactory
By using Kraft paper, Sonhab Chocolate was able to create a reliable and durable package that could house their hand-crafted chocolates and allowed for an absorbent kraft paper surface for handwritten notes.
The Kraft paper paired with foil-stamped details also provided a rustic look and feel that aligned with their branding and commitment to sustainability.
By choosing Kraft paper, Sonhab Chocolate was able to create a unified branding experience while remaining true to their values and commitment to sustainability.
The use of Kraft paper not only enhanced the customer experience but also helped them to reduce their carbon footprint and minimize waste, making it a win-win solution for both the business and the environment.
Read more about Sonhab Chocolate’s Packaging