PACK EXPO 2026: Sustainable Packaging Trends for Brands and Converters

Oct 23rd 2026

PACK EXPO 2026: Sustainable Packaging Trends for Brands and Converters

This year, PACK EXPO International ran October 18–21, not too far from our office, and our team was there to see what's next.

Step into the show floor and you'll see endless rows of robots palletizing, printers coding at full speed, and filling lines running nonstop. Beyond all that machinery innovation, a quieter story is playing out: brands are rethinking what their packaging is made of, how it performs, and where it goes when the job is done. This is what circularity is all about, and it's the next frontier of sustainable packaging.

For sustainable brands, circular packaging experts, and innovative converters exploring sustainable packaging solutions, from recyclable, FSC certified, compostable, and recycled-content materials to reusable systems and compostable flexible packaging, the question is becoming more practical (1) what works for your product, (2) your production line, and (3) your waste recovery pathway? Here’s what we took away.

The Big Picture: Sustainability Got Specific

Sustainability wasn't a side topic this year. It was built into the show itself, from its Sustainability Central stage to a curated Sustainability Solutions Finder.

  • EPR is here. Extended Producer Responsibility laws have moved from "coming soon" to "in effect." One Sustainability Central session put it plainly: 2026: The Year EPR Stopped Being Optional. (New to EPR? Start with our guide to compostable packaging and EPR.)
  • Recyclability and recycled content led the awards. Two of PMMI's three Technology Excellence Award winners focused on recyclable mono-material and recycled content: Mitsui Chemicals' water-based barrier coating and Amcor's 100% PCR tube.

Those were the headlines. But three trends stood out to us because they connect directly to what we care about most: eliminating packaging waste and making composting work.

Trend #1: Sustainable Packaging Has to Prove It Performs

The first trend we saw: a sustainability claim wasn't enough on its own. Packaging has to protect the product, run on the line, and hold up in distribution.

You could hear it in the session titles:

  • Protect the Product, Reduce the Footprint (Sanner Group)
  • Can a Multipack Be Sustainable If It Doesn't Perform? (PakTech)
  • Packaging Sustainability Myth Busters: Beliefs that Brands Still Get Wrong (Amcor)

For example: Sustainable flexible films often have a narrower heat-seal range than the structures they aim to replace. Without the right equipment, lines slow down and waste more.

PMMI's latest research backs this up. In The Ripple Effect, PMMI found that:

  • 82% of end users are actively pursuing sustainability initiatives
  • Over half say machinery limitations keep them from meeting their sustainability goals

Our take: A sustainable package that fails in production creates waste, replacement shipments, and more packaging, contradicting its sustainability. Performance and end of life belong in the same conversation.

Trend #2: The "Small Stuff" Got Big Attention

In 2024, we wrote about the hidden plastics in business: the tape, stretch wrap, shrink bands, labels, and gloves that rarely make it into conversation. At PACK EXPO 2026, those overlooked components finally had the spotlight. For brands conducting a sustainable packaging audit, these components deserve the same scrutiny as the primary package. Compostable labels, packaging tape, tamper-evident seals, and pallet wrap can help address overlooked plastic waste streams, but each component needs to meet its performance requirements and fit the intended disposal pathway.

  • Case-sealing tape. Shurtape's session What's Next for Packaging Tape? framed the case seal as a real lever for cutting virgin plastic in end-of-line operations.
  • Closures. Colorcon's OneLock closure won PMMI's Technology Excellence Award for combining child-resistant and tamper-evident features with a built-in desiccant in a single part.
  • Grease barriers. Archroma introduced a PFAS-free, bio-based oil and grease barrier for food packaging, and Sappi showcased a grease-resistant, compostable foodservice board.

Our take: One roll of tape or one shrink band seems insignificant, but multiply it across thousands of shipments and it becomes a waste stream. A compostable pouch with a plastic label still has a plastic problem.

Trend #3: Compostable Packaging Is Growing, With a Clearer Job to Do

Here's where we want to be honest: compostable packaging wasn't the headline at PACK EXPO 2026. By our count, compostable came up in 5 of the show's 152 education sessions, while 32 sessions discussed recyclability.

But the companies that did show up made a strong case for where compostable packaging fits:

  • Mitsui Chemicals presented water-based coatings that make recyclable and compostable paper cups possible by replacing conventional plastic linings.
  • Kaneka Green Planet introduced new home-compostable cutlery for 2026.
  • Archroma showed a PFAS-free, bio-based grease barrier for food packaging, where grease and food residue make recycling difficult.

Our take: Circular compostable packaging can serve applications where practical reuse or recycling pathways are limited, including certain flexible films, multilayer packaging, and food-soiled packaging. For brands comparing compostable versus recyclable packaging, the right choice depends on product protection, collection infrastructure, and what actually happens after use, including microplastics and related follow on health concerns.

Compostability delivers on its promise when certified materials, compatible components, clear composting instructions, and access to composting facilities, including an effective take-back program, come together.

Packaging Innovations to Watch Now

Beyond individual materials, the opportunity is in how the whole packaging system works. These are the areas to watch as they're rapidly evolving:
  • Recyclable mono-material packaging: Simplifying material structures while maintaining barrier performance and product protection.
  • Paper-based packaging and sustainable barrier coatings: Improving resistance to moisture, oxygen, and grease while checking how coatings affect recycling or composting.
  • Post-consumer recycled content: Evaluating how PCR materials perform on existing equipment and meet product requirements.  This is a current trend but predict PCR will diminish significantly with respect to PCR plastic due to growing cost limitations and increasingly more microplastic concerns which could introduce barriers as legislation continues to mature.
  • Compostable flexible packaging: Matching films, pouches, labels, and closures to suitable applications and available composting pathways.
  • Reusable transport packaging: Reducing single-use materials where reliable return and reuse systems are available.
These innovations represent different approaches to circular packaging. The useful question is which approach can protect the product and deliver a credible outcome in the system where it will be used.

What This Means for Your Brand: A Quick Checklist

  • Know your EPR exposure. Check which states you sell into and what reporting, fee, and design requirements apply to your packaging.
  • Audit every component. List the tape, labels, seals, shrink bands, gloves, and wrap your operation uses, not just the primary package.
  • Test before you commit. When sourcing custom compostable pouches, coffee bags, cellophane bags, or printed rollstock to test with your own product and equipment. Evaluate sealing, barrier requirements, shelf life and shipping conditions.
  • Check certifications and disposal access. Look for recognized composting standards such as ASTM D6400 and EN 13432, confirm local acceptance, and give customers clear disposal instructions.
At Elevate Packaging, our focus is helping brands and converters move from sustainability goals to packaging that performs, and consistently gets composted.
From compostable PSA labe materials, natural wood pulp cellophane, and bio-based laminations to convert into stand-up pouches, coffee packaging, label stickers, and more, we help match the compostable materials and packaging solutions to the product and a reliable composting pathway.

Because the future of packaging isn't just about what happens on the line. It's about what happens after.

Ready to explore sustainable packaging for your business?  Explore our compostable packaging or connect with one of our Zero Waste Ambassadors

Frequently Asked Questions

When and where was PACK EXPO International 2026?

PACK EXPO International 2026 took place October 18–21, 2026, at McCormick Place in Chicago. The show is held in Chicago every two years and featured 2,700+ exhibitors and 150+ free education sessions.

What were the biggest packaging trends at PACK EXPO 2026?

EPR compliance, recyclable and recycled-content materials, reuse, fiber-based packaging, and automation and AI led the show. Sustainability conversations focused on proving performance and on overlooked components like tape, stretch wrap, closures, and labels.

Is compostable packaging still growing?

Yes, selectively. Among PACK EXPO International 2026 registrants surveyed by PMMI, more attendees planned to switch into compostable materials than out of them (net +7.4%). Many new adopters are moving away from multi-material and plastic flexible films and foam.

What is EPR, and why does it matter for packaging?

Extended Producer Responsibility laws shift the cost of managing packaging waste onto the brands and producers that put packaging on the market. Several U.S. states now have programs in effect, with reporting requirements and fees that can vary based on a package's material, design, and end-of-life outcome.

What's the difference between reusable and compostable packaging?

Reusable packaging is designed to be used many times, like pallets, totes, and refillable containers. Compostable packaging is designed for single use and breaks down under specified composting conditions. Many brands use both: reuse where packaging can come back, and compost where it can't.

How do I know if packaging is really compostable?

Look for certification to recognized standards such as ASTM D6400 or EN 13432. Check that every component, including the film, label, seal, and closure, is covered. Then confirm that a composting facility in your area accepts it.

Additional Resources

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