For a long time, vacuum skin packaging has been inextricably linked with plastic trays. However, a green movement emerging in 2026 is completely transforming this perception.
Cardboard-based vacuum skin packaging is emerging as one of the industry's most closely watched market segments. According to the latest forecast by Future Market Insights, this segment is projected to grow from $6.2 billion in 2026 to $11.4 billion by 2036, with a compound annual growth rate (CAGR) of 6.2%. The technology involves using a lightweight cardboard sheet as a base, then vacuum-sealing a high-barrier film tightly against both the cardboard and the product surface to form a recyclable fiber-based packaging structure. This paper-plastic hybrid solution not only reduces plastic usage by nearly 50% but also allows the cardboard component to enter traditional paper recycling streams directly, reducing the carbon footprint of single-use plastic packaging at the source.
To adapt to this trend, skin packaging equipment is also undergoing rapid evolution. Leading equipment manufacturer ULMA has introduced a skin sealing system in its R-Skin series that works with lightweight cardboard trays, reducing material usage by up to 50%. Meanwhile, its CUT ONTRAY cutting system further reduces top film waste by 30%. Another significant technological advancement stems from the widespread adoption of single-material solutions. As regulations such as the EU's Packaging and Packaging Waste Directive become increasingly stringent, more multinational food companies are opting for skin packaging bottom and top films made from the same base resin. This design enables full recyclability of the entire package without compromising high oxygen barrier performance.
As the food processing industry adopts an increasing number of smart skin packaging machines capable of monitoring production status, packaging lines can not only reduce manual intervention during high-speed operation but also precisely control vacuum levels and sealing temperatures for each seal. This ensures consistent sealing results even with new materials such as cardboard substrates and biodegradable films.
