Ditch the Plastic: Making the Eco-Conscious Switch to Kraft Paper Rolls

What kraft paper rolls are

Kraft paper rolls are large continuous rolls of paper produced using the kraft (sulfate) pulping process. They are typically brown (unbleached) but can also be bleached or treated for special properties (grease resistance, moisture resistance, printing surface). Sold in a variety of widths, lengths, and weights (grammage), kraft paper rolls are designed for industrial and retail packaging tasks such as wrapping, void filling, cushioning, and surface protection.

Why switch from plastic to kraft paper rolls

Switching to kraft paper rolls replaces many single-use plastic packaging items—like poly bags, bubble wrap, and stretch film—with a material that is renewable, widely recyclable, and often compostable. Customers increasingly prefer sustainable packaging, and many jurisdictions are encouraging or regulating reductions in single-use plastic. Kraft paper typically has a smaller end-of-life environmental impact when sourced and managed responsibly, and it supports a circular materials approach when recycled or composted.

Common uses in warehouses and fulfillment

• Order wrapping for apparel, home goods, and low-fragility items.
• Void fill: crumpled kraft for cushioning, replacing inflated plastic air pillows.
• Interleaving and surface protection during storage and transport.
• Gift wrapping and branded wrapping with water-based inks or stamps.
• Paperboard and corrugate cores for custom inserts and edge protection.

Types and options

Choose kraft rolls based on end use:

• Unbleached brown kraft: most common, strong, and low-cost.
• Bleached/white kraft: better for high-quality printing or retail presentation.
• Recycled kraft: contains post-consumer or post-industrial fiber to reduce virgin pulp use.
• Coated or treated kraft: grease-resistant or moisture-resistant variants for food or oily products (note: some coatings can affect recyclability).
• Pre-printed or branded rolls: for logos, return labels, or messaging using water-based inks.

How to pick the right kraft roll

Key factors to consider are grammage (GSM), width, core diameter, and whether you need special coatings or printing. Lower GSM (e.g., 30–60 gsm) works for light wrapping and void filling; mid-range (80–120 gsm) is good for general wrapping and e-commerce parcels; heavier weights (>120 gsm) serve for protective wraps and tray lids. Match roll width to your workstation and dispenser; choose a core size compatible with your cutters and machines.

Implementation best practices for warehouses and e-fulfillment

1. Run a small pilot: test different GSMs and roll sizes to find the best balance of protection, cost, and usability.
2. Train staff on efficient tearing, scoring, and folding techniques to avoid waste and speed packing times.
3. Use dispensers and cutters to improve ergonomics and reduce roll jams; automatic dispensers can improve speed for high-volume operations.
4. Pair kraft with targeted protective materials: use corrugated inserts, paper honeycomb, or molded pulp for fragile items rather than over-wrapping with heavy material.
5. Standardize box and roll sizes across SKUs to simplify procurement and reduce leftover waste.

Environmental considerations and certifications

Look for responsibly sourced certifications such as FSC or PEFC to confirm sustainable forestry practices. Recycled-content kraft reduces demand for virgin fiber. Be aware that some coatings, laminations, or inks can impair recyclability or compostability; prefer water-based inks and recyclable coatings when possible. Share clear disposal guidance with customers: kraft paper can usually be recycled with paper streams if free of grease, heavy coatings, or food residue, and many uncoated kraft papers are industrially compostable.

Cost and operational impacts

Kraft paper often costs more per unit area than some low-cost plastics, but lifecycle advantages (lower disposal fees, improved brand value, and easier compliance with regulations) frequently offset the price difference. Operationally, switching reduces plastic inventory types, simplifies returns packaging reasoning, and can lower anti-static or contamination issues associated with some plastic films.

Common mistakes to avoid

• Under-specifying protection: using lightweight kraft only will not protect fragile items—combine with suitable inserts.
• Neglecting moisture and grease risks: uncoated kraft is vulnerable to water and oil contamination, which can make it unsuitable for some food or industrial products unless treated.
• Using non-recyclable coatings or inks: these negate environmental benefits—choose recyclable or compostable treatments.
• Over-packaging: relying solely on thicker paper rather than smarter design increases cost and waste.

Practical examples

Small e-commerce brands often move from plastic poly mailers and bubble wrap to kraft paper rolls plus kraft mailers. A small clothing retailer can wrap garments in kraft sheet, use crumpled kraft as void fill, and ship in a kraft mailer—reducing visible plastic and simplifying consumer recycling. For breakable items, a combination of kraft paper wraps and molded pulp or corrugated edge protectors delivers protection comparable to bubble wrap with better end-of-life outcomes.

Storage and handling tips

Store rolls in a dry environment on pallets or roll racks to prevent moisture absorption and deformation. Rotate stock FIFO to avoid long-term exposure that can weaken paper or attract pests. If using treated kraft, keep separate inventory and label clearly to prevent accidental mixing with standard recyclable kraft.

Customer communication and marketing

Highlight the switch on packing slips, website product pages, and social media with simple messaging that explains how to recycle or compost the kraft packaging. Clear instructions reduce contamination in recycling streams and enhance brand perception—customers appreciate straightforward guidance like “Tear off tape, flatten, and recycle with paper.”

When plastic still makes sense

Kraft paper is not always a direct drop-in for plastic. Use plastic alternatives when moisture barrier, puncture resistance, or transparency are strictly required (for example, liquid products, heavy outdoor exposure, or tamper-evident sealed pouches). Where possible, consider bio-based or recyclable plastic films as a transitional option and always evaluate the full supply chain and disposal pathways.

Final practical checklist

1. Select GSM and roll width that suit your SKU mix.
2. Choose FSC/PEFC or recycled-content options where possible.
3. Test packing procedures and protective pairings for fragile items.
4. Install efficient dispensers and train staff on speed/waste reduction techniques.
5. Label and educate customers about recycling or composting steps.

Switching to kraft paper rolls is a practical, beginner-friendly step toward reducing single-use plastics in packing operations. With the right selection, training, and communication, kraft can deliver a cleaner end-of-life for packaging, stronger brand credentials, and a simpler path to regulatory compliance.