Every year, approximately 855 billion sachets are used worldwide to package products such as ketchup, mustard, cooking sauces, and hand cream. However, these three-layer composite sachets-typically composed of polyolefins, aluminum foil, and polyester-are virtually impossible to recycle, placing a massive strain on the environment. In 2026, a breakthrough emerged: a fully compostable liquid sachet packaging solution based on cellulose film officially hit the market, marking the first time small-volume liquid packaging has achieved a sustainable, compostable solution suitable for both industrial and household settings.
The Environmental Paradox of Pouches: The Price of Convenience and Pollution
Pouch formats are widely used globally due to their convenience-they can be torn open with one hand and are designed for single-use portability. However, this convenience comes at a heavy environmental cost. According to industry estimates, approximately 855 billion pouches were used worldwide in 2018 alone.
The problem lies in the packaging structure. Most small pouches use a three-layer composite structure containing incompatible materials such as polyolefins, aluminum foil, and polyester, which are nearly impossible to separate and recycle within existing recycling systems. Even more challenging is that these pouches are tiny and often contaminated with food residues, further complicating the recycling process. These tiny composite plastic packages often end up in the environment, becoming a major source of microplastic pollution.
Technological Breakthrough: Cellulose-Based Film Achieves Full Biodegradability
In February 2026, compostable film manufacturer Futamura, flexible packaging processor Repaq, and machinery manufacturer GK Sondermaschinenbau jointly announced the successful development of a fully biodegradable and compostable liquid pouch solution based on NatureFlex™ technology. This solution is capable of packaging liquid products such as ketchup, mustard, cooking sauces, and hand cream.
The core innovation of this technical solution lies in the material selection: the new compostable composite consists of a barrier cellulose film from Futamura and a bio-based film layer to ensure an airtight seal. This structure has received dual certification for both industrial and home composting, meaning consumers can achieve complete degradation whether they dispose of it in industrial composting facilities or home compost bins.
The performance data is equally impressive. Under standard conditions (23°C, 50% relative humidity), the oxygen transmission rate of this liquid packaging is as low as 0.5, supporting a shelf life of up to 12 months. More importantly, in terms of production efficiency, there is no difference in production efficiency when using this structure compared to conventional structures-a performance that has been repeatedly validated on small, medium, and large GK Sondermaschinenbau machines. Repaq's technical manager confirmed that, following two years of collaborative R&D, the new packaging delivers significant ecological benefits while providing excellent product protection.
Industry Implications: Providing a Solution for "The Most Difficult Packaging to Recycle"
Liquid pouches have long been regarded as one of the "most difficult packaging types to recycle." The significance of this fully compostable solution lies not only in its technical breakthrough but also in the fact that it charts a new course for the entire flexible packaging industry-moving away from reliance on the perfection of recycling systems and instead designing for the "end-of-life" of materials from the source.
The first commercial pouches utilizing this compostable structure are about to enter the market. The Sales Director at GK Sondermaschinenbau stated that during testing, the solution required virtually no adjustments to existing equipment. Futamura's Regional Sales Manager pointed out that this home-compostable liquid pouch packaging truly meets the market's demand for comprehensive sustainable packaging solutions in both the food and non-food sectors.
Meanwhile, the overall market for bio-based materials is also experiencing rapid growth. According to industry statistics, the global bio-based materials market is expanding rapidly at a compound annual growth rate (CAGR) of 22%, and is projected to reach $57.83 billion by 2026. The market for bio-based pouch materials is projected to grow from $735 million in 2025 to approximately $1.256 billion by 2035, at a CAGR of 5.5%, driven primarily by the food industry's demand for sustainable packaging.
The emergence of fully bio-degradable liquid pouches marks a departure from the vicious cycle of "single-use-non-recyclable-environmental pollution" in the small-volume liquid packaging sector. From three-layer composite plastics to fully cellulose-based compostable structures, this technological path demonstrates that even the most challenging packaging formats can achieve a closed-loop environmental solution through material innovation. For industries such as food and beverage and personal care-which rely heavily on pouch packaging-this is not only a compliance-driven choice but also a vital component of a brand's sustainability narrative.
