Wayfarer Barrier Paperboard | Recyclable Paper Alternative to Fossil Soft Plastic Bags and PET/rPET Punnets

The challenge addressed was supplying a sustainable packaging solution that helps maintain fresh produce quality while reducing packaging waste. Many fresh produce categories require packaging with effective moisture and gas barrier properties to prevent shrivel, moisture loss, flavour degradation, and food waste throughout the supply chain. Currently, PET/rPET/softplastic plastic packaging is widely used due to its performance, despite being made from non-renewable materials and having low global recycling rates. Wayfarer is a recyclable paperboard/punnet capable of delivering effective barrier performance for different fresh produce types, particularly high-respiration produce, while remaining compatible with existing supply-chain and shelf-life-requirements.

The Wayfarer is a recyclable, barrier paperboard alternative to conventional PET/rPET/soft-plastic fresh produce packaging. Designed to reduce fruit waste and help maintain product quality, the paperboard aims to help manage moisture loss and shrivel. Development involved extensive technical trials, material testing, and design refinements. The final solution delivers both product protection and recyclability within existing paper waste streams.

The Wayfarer delivers environmental, commercial, and supply chain benefits by replacing conventional plastic fresh produce packaging with a recyclable paperboard alternative. The solution reduces reliance on non-renewable plastic materials while helping manage food waste through managing shelf-life performance and fruit quality. Commercially, it provides growers and retailers with a sustainable packaging solution that fits in with logistics, and retail systems. Societally, the project supports the transition toward circular packaging systems by enabling recycling through standard paper waste streams and responding to increasing consumer and industry demand for more sustainable packaging solutions. Paperboard punnets/packaging are essential in pacific islands.

Barrier coated paperboard engineered to deliver barrier performance for fresh produce applications.Designed to help reduce fruit shrivel, moisture loss, and food waste while maintaining freshness, flavour, and shelf life.Recyclable within existing paper waste streams, providing an alternative to conventional PET/rPET/soft plastic plastic packaging.Structurally optimised to maintain pack strength, pallet efficiency.Suitable for existing post-harvest packing and retail systems.Technical trials and collaboration across growers, pack houses, and retailers.Supports circular economy outcomes by reducing reliance on non-renewable plastic materials.PFAS free