In the packaging sector, companies are facing increasingly complex challenges: from rapidly evolving regulations in the United States and Europe, to new R&D investments aimed at developing innovative, safe and sustainable materials. Added to this is the growing attention toward potentially harmful substances in food packaging, a topic of rising importance for consumers, buyers and distributors. Finally, the expansion of e-commerce continues to highlight the need for solutions specifically designed for direct-to-consumer shipping.

Harmful substances: consumers increasingly attentive and buyers under pressure

Awareness of potentially harmful substances in food packaging is rising. Consumers, buyers and distributors are demanding clearer proof of safety and greater transparency regarding material composition.

Among the main chemical substances considered "chemicals of concern" and currently under scrutiny are:

• PFAS (perfluoroalkyl substances), used for grease and water resistance; many are now classified as forever chemicals because they persist in the environment without degrading. PFAS are associated with potential health risks, including endocrine disruption, immune system issues and a higher likelihood of certain cancers.

• BPA (Bisphenol A), used in some polycarbonates and epoxy resins, subject to strict restrictions in the EU but still found in many food-contact applications. Concerns persist regarding its endocrine-disrupting potential and the risk of migration into food and beverages, especially under heat or prolonged storage. Children are considered particularly vulnerable due to their developing metabolism. Exposure to BPA has been linked to neurological development issues, higher risk of obesity and diabetes, fertility problems, cardiovascular impacts and possible associations with certain cancers.

• Phthalates, widely used as plasticizers in PVC and flexible packaging. Exposure has been linked to various health effects, including fertility disorders, neurobehavioral development issues in children, obesity, insulin resistance and increased risk of cardiovascular disease and certain cancers.

• Styrene and derivatives, the subject of ongoing debate regarding food-contact safety. Styrene is classified as "probably carcinogenic to humans," and exposure - especially by inhalation or in workplace environments - has been associated with blood cancers, central nervous system damage, respiratory issues, and potential effects on the liver, kidneys and reproductive system.

• Polycyclic aromatics and residues from printing inks not suitable for food contact. Polycyclic aromatic hydrocarbons (PAHs) and residues from non-food-grade inks may still be found in certain packaging, particularly when recycled materials are used or when printing is applied to the outer surface but can migrate or transfer by "set-off." Although covered by general food-contact regulations, the lack of a specific European framework on inks means prevention depends heavily on manufacturers' choices and supply chain controls. These substances are associated with genotoxic effects and increased cancer risk.

• MOSH and MOAH (mineral oil saturated and aromatic hydrocarbons), typically originating from recycled paper and cardboard, mineral-based inks and certain adhesives. Migration into dry foods - such as pasta, rice, cereals, snacks and baked goods - is well documented. MOSH tend to accumulate in tissues and may affect the liver and lymphatic system, while MOAH are considered potentially carcinogenic even at low concentrations.

• Primary aromatic amines (PAA), which can form from certain dyes, inks and adhesives used in paper, plastic or multilayer packaging. Under humidity, heat or insufficient barrier conditions, these substances may migrate into food. PAAs are associated with genotoxic effects and potential cancer risks, prompting ongoing monitoring by health authorities.

Buyers - especially in large-scale retail and international distribution - are increasingly requesting stricter certifications, declarations of absence of critical substances, full material traceability and more frequent migration tests to ensure that no unwanted chemicals migrate into food. The market message is clear: safer packaging with transparent composition and compliance with international standards.

Is the "free-from" claim enough?

In recent years, the "free-from" claim is no longer seen as sufficient in food packaging. Buyers and consumers - now more aware of risks related to PFAS, BPA, phthalates, MOAH, PAA and other substances capable of migrating from packaging into food - are seeking stronger assurances than the simple absence of a single compound. Growing attention to chemical safety, supported by increased access to information and more restrictive retail guidelines worldwide, requires packaging supported by migration tests, independent certifications and transparent material traceability.

For this reason, manufacturers can no longer rely solely on a "PFAS-free" or "BPA-free" claim, but must demonstrate - through verifiable data - the overall safety of packaging (ideally covering a broad range of potentially harmful substances) and its compliance with increasingly demanding standards.

Regulatory evolution: from the United States to Europe

Beyond health concerns, the environmental dimension has become central in the evaluations of consumers and buyers.

New regulations - introducing strict limits and ambitious impact-reduction targets - are also reinforcing public awareness of ecological issues.

Packaging legislation is evolving rapidly on both sides of the Atlantic. In the United States, an increasing number of states are adopting Extended Producer Responsibility (EPR) frameworks, requiring producers to finance recycling and end-of-life management. Meanwhile, in Europe, the regulatory environment is being strengthened. The Packaging and Packaging Waste Regulation (PPWR) sets strict goals for reuse, reduction of unnecessary packaging and minimum recycled content, alongside new design requirements and greater accountability for producers and importers.

For companies, this means managing complex compliance, updating production methods, revising material choices and defining clear processes to ensure circularity.

The e-commerce gap: packaging not specifically designed

The continuous growth of e-commerce is exposing a widening gap between consumer expectations and the packaging solutions many companies still use. Much of the packaging currently on the market was designed for traditional in-store sales and not for the demands of online shipping - logistics hubs, repeated handling and last-mile delivery.

When packaging is not designed for this journey, the risk of transport damage increases significantly. This leads to more returns - with economic and environmental consequences - and can undermine consumer confidence when products arrive in poor condition.

To meet digital market expectations, packaging for e-commerce must be more robust, capable of passing specific tests such as ISTA standards, easy to open, easily recyclable and suitable for efficient handling of returns. At the same time, food products require additional protection to maintain quality, safety and proper preservation throughout the entire logistics chain. However, many companies have yet to adopt fully adequate solutions, making this gap one of the key challenges for the coming years.

Research, development and new technologies

The push toward new materials and more advanced solutions has become essential for companies across the industry. Today, packaging R&D focuses on four main areas: materials, safety, sustainability and health.

Innovative and high-performance materials

Companies are investing in high-performance biopolymers, next-generation compostable plastics, reinforced cellulosic materials and monomaterial solutions designed to simplify recycling. The goal is to develop packaging with mechanical strength, long-term stability and optimal product preservation - while requiring minimal adjustments to existing production and packaging processes.

Food safety

R&D also focuses on developing more effective barriers against oxygen and moisture, coatings free from potentially problematic substances and systems that enhance the overall safety of contents - such as tamper-evident features and active packaging designed to limit microbial growth. These advancements respond to a market increasingly attentive to protection and shelf-life performance.

Environmental sustainability

Sustainability goes beyond adopting "green" materials and involves rethinking the entire packaging life cycle - recycling-oriented design, weight reduction, logistical optimization and minimization of overall environmental impact. In this process, Artificial Intelligence is playing a growing role: supporting material selection, simulating packaging behaviour, accelerating prototyping and enabling early environmental impact assessments.

Advanced technologies for monitoring contaminants in food-contact materials

Alongside material innovation, increasingly advanced technologies are emerging for the independent monitoring of substances in food-contact materials. Laboratories, research institutes and specialised companies are adopting tools such as high-resolution mass spectrometry, chromatography with automated systems and AI-based predictive platforms. These technologies allow more precise identification of both known substances and NIAS (Non-Intentionally Added Substances), often responsible for unwanted migration. The growing demand for independent testing - driven by consumers, buyers and retailers - is becoming essential to verify the absence of contaminants, strengthen trust in food packaging and ensure regulatory compliance.

Better-informed consumers: the impact on perceptions, risks and purchasing

Consumers are increasingly seeking detailed information on safety, sustainability and health-related aspects. Traditional media (press and TV), social media, scientific outreach websites, institutional sources and user-generated content all contribute to rapidly spreading news, studies and case reports on food-contact materials.

Greater exposure to simplified - yet highly influential - technical content is reshaping risk perception and steering purchasing decisions toward products considered safer, more sustainable or free from controversial substances.

In this scenario, food companies, packaging manufacturers, distributors and retailers can adopt more transparent solutions, safer materials and clearer communication to respond to evolving consumer expectations and build trust.

Industry studies, surveys, forecasts and market analyses consistently indicate that in the coming years, purchasing preferences will continue to favour products and packaging perceived as safer, more sustainable and more health-conscious, driving the entire supply chain toward more responsible and transparent choices.