Kevin Lee spoke with Sal Pellingra, VP Global Package Design, Applications and Business Development at ProAmpac, about how flexible packaging can improve both environmental impact and cost—while reshaping how consumers experience products.
Pellingra says ProAmpac comes to Expo West to meet brands at all stages that share a common challenge: getting to market quickly and sustainably. ProAmpac specializes in flexible packaging, with capabilities in prototyping, short-run digital printing, and an expanding range of sustainable solutions. These include fiber-based materials that can go straight into curbside recycling, and films designed for store drop-off programs. Walking the show floor, Pellingra sees many products where packaging could easily be made more recyclable or converted to fiber without sacrificing performance.
One of the biggest misconceptions he encounters is that eco-friendly packaging always costs more. In reality, moving from rigid to flexible packaging can reduce plastic usage and total system costs. Flexible packs are lighter, take up less space, and lower shipping and distribution expenses. He points to secondary packaging—such as multi-packs—where a simple paper wrap can be a very economical outer layer, while inner packs provide the barrier needed for shelf life. Just as important, ProAmpac’s sustainable designs are engineered to run at equal or faster speeds than traditional, non-recyclable materials, helping brands shift toward a more circular economy without slowing down operations.
Demand for sustainable packaging is being driven from multiple sides: consumers, brands, and retailers. Consumers are increasingly asking whether the packaging they see is “bad for Mother Earth” or something they can feel good about buying. At the same time, brands are working to fulfill their sustainability and carbon reduction commitments, and retailers are setting their own requirements for what they will carry. ProAmpac steps into this space by offering tailored packaging solutions that help brands meet their goals, support retailer standards, and align with consumer expectations.
Social media has added a new dimension. Platforms like TikTok and YouTube have turned unboxing into a public, often critical, stage. Pellingra highlights how many unboxing experiences reveal wasteful practices—like receiving an item “about the size of a baseball” in a foot-and-a-half square box. Over-packaging frustrates customers and becomes easy fodder for viral criticism. This visibility pushes brands to rethink their choices, especially in e-commerce, where packaging decisions are magnified at the doorstep.
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