6 main challenges of manufacturing cardboard food packaging

Cardboard food packaging has come a long way from plain boxes to high-performance, food-safe designs. Today, manufacturers juggle durability, cost, sustainability, and compliance — all while keeping food fresh and appealing. From grease-resistant coatings to moisture barriers, innovations are making packaging stronger and safer without losing sight of consumer expectations.

Sustainability is more than a trend; it’s now a standard. Customers and regulators alike want recyclable, compostable, and biodegradable options that perform as well as traditional materials. The real win comes when packaging is both eco-friendly and functional — protecting food, cutting waste, and supporting a circular economy.

Behind every great package is a thoughtful design process. User-friendly shapes, stackable structures, and custom branding all add value while meeting strict food safety regulations. It’s this balance of creativity, compliance, and practicality that drives the best results in the industry.

Bringing safe, durable, and sustainable packaging to market takes more than good design — it takes expertise at every stage. That’s where Intertek’s packaging solutions come in. From food contact testing and regulatory compliance to sustainability assessments and performance optimization, we help manufacturers and food businesses deliver packaging that meets global standards. Contact us to see how we can support your next project.