From lab to launch: Abigail Sawyer-Parker’s very personal journey of packaging evolution

Paper packaging – rooted in millennia-old traditions such as those dating back to the Tang Dynasty in China – is experiencing a resurgence driven by modern innovation. Today, paper packaging is not merely nostalgic but increasingly pivotal in everyday life, buoyed by a global shift towards sustainable alternatives to plastic. You only have to walk the floor of Packaging Innovations & Empack to witness firsthand the evolution of this trend, showcasing improved functionality, recyclability, and new aesthetic developments year after year.

“It’s exciting to be part of it from the early stages,” says Abigail. “There are endless possibilities and significant room for improvement in new categories. It’s an exciting time. I did a lot of research, trying to apply information from other scenarios to paper. I worked closely with the innovation teams in America because we got a lot of projects through. If I wasn’t sure about something, I’d ask the team, and they might say, ‘Oh, we worked on this in 2022, and we got these results’, then it’s about applying that knowledge to what you’re doing.

“I am probably too excited about my projects because I am very invested. This isn’t just a job for me; it’s a career. For example, with the M&S Organics range, we won at the Environmental Packaging Awards. The development work for that has been ongoing since I started in 2021. Now, it’s finally on the shelves and winning awards, and I can see the result of four years of work. The average consumer might think, ‘Oh, that’s on paper now, nice’, but the amount of trial, material development, and testing that has gone into that project is immense.”

With a keen eye for sustainable solutions and a proactive approach to challenges, Abigail continually pushes the boundaries of what is possible in packaging technology. Her ability to navigate complex projects and deliver exceptional results has made her a formidable force in her field, earning recognition and respect from peers and industry leaders. Abigail’s competitive spirit drives her to continually seek new opportunities for growth and impact, solidifying her reputation as a leader and trailblazer in the packaging industry.

“With high barrier developments, it’s not just about putting a coating on paper; it’s about sourcing the right type of paper for the coating and optimising the processes,” she explains. “If we can’t run it through the factory efficiently there’s no point. So, it’s not just material development; we need to understand how the factories work and the processes that make something commercial.

“It’s nice to be at the forefront of this, especially being so new to the industry, but it’s also quite challenging. It’s a competitive space. Seeing other companies launch products injects excitement into our roles. We try to identify consumer needs and wants before they become widespread. For instance, we just launched ProActive Recyclable RP-1050EU to replace shrink wrap and secondary packaging, anticipating the PPWR. We aim to stay ahead of the trends to offer established solutions to our customers.”

She goes on: “Navigating the complexities of packaging materials prompts us to balance functionality with sustainability. And that often involves candid conversations with customers. ProAmpac explains that while their materials may meet their product’s needs, operational constraints on packaging machinery can complicate adoption. This journey of education intersects where recyclability and performance meet.

“It’s tricky because from the material science side, if I walk into a store and see a pack of whole onions in paper, I think, ‘Oh, that’s cool. That’s nice. That works for the product’. But then you start to wonder how they are overcoming the barrier to that. What’s inside? We receive a lot of inquiries for items like protein bars and natural fruit and nut bars. They require a high barrier, but there’s a strong push to switch to paper due to the fiberisation trend. It’s often a matter of explaining to the customer that we have a material that works for their product, but it might not run on their machine. Or we have a paper that will run on their machine, but we’re unsure if it suits the product.

“So, it’s also about educating the customer because they’re keen on paper for its curbside recyclability. But sometimes, we think their product would fare much better if they used a recyclable OPP laminate instead. We believe in solutions where possible, but we won’t force them. You see a lot of that happening without considering all the factors.”

Abigail’s journey from biochemistry to packaging technology epitomises the unexpected paths that lead to passion and purpose. Rising swiftly in ProAmpac, her groundbreaking work in sustainable packaging, including developing ProActive Recyclable® paper sachets, underscores her commitment to innovation and environmental responsibility. Her accolades, like the Future Trailblazer Award, highlight her rapid ascent and the transformative impact of her contributions to the industry.

In a field where function meets sustainability, Abigail navigates complex challenges with a blend of scientific rigour and strategic vision. Her story inspires a broader narrative of resilience and exploration, reminding us that true fulfilment often emerges when we embrace new opportunities and push the boundaries of what’s possible. Abigail demonstrates that by following our passions and leveraging our skills, we can succeed and lead meaningful change in our industries and communities.