Corrugated Packaging Trends for 2025: Sustainability, Innovation, and AI

As we welcome the excitement and opportunities of a new year, we wanted to look at the key trends that will shape corrugated packaging in 2025. As an innovative and forward-thinking industry, corrugated packaging continues to evolve, driven by the increasing need for environmentally-friendly packaging, new technological and product development, and meeting changing consumer demand. Here are some key trends for 2025:

1. Continued focus on sustainability

Environmental concerns are reshaping the packaging landscape, and corrugated materials are well-positioned to meet these demands. In 2025, expect a heightened focus on reducing carbon emissions across the supply chain. Customers are pushing for corrugated packaging made with higher percentages of recycled content, along with a desire to source lighter weight corrugated material usage that doesn’t compromising durability.

The rise of circular economy models will also influence packaging practices. Manufacturers are exploring closed-loop systems where corrugated boxes are recycled into new packaging at scale. Water- and solvent-free adhesives, alongside more efficient production methods, are being adopted to make the manufacturing process cleaner and greener.

Find out more about ASC Direct's commitment to reducing environmental impact.

2. AI design

Artificial intelligence is revolutionising the way corrugated packaging is designed. By leveraging AI algorithms, companies can create innovative designs tailored to specific needs. For instance, AI can analyse product dimensions, shipping requirements, and even consumer preferences to produce custom-fit, efficient, and visually appealing packaging.

AI tools also allow rapid prototyping by automating structural and aesthetic design processes. This accelerates the development of packaging that balances functionality with branding objectives. Moreover, predictive analytics driven by AI can forecast demand, ensuring manufacturers produce the right quantity of packaging at the right time, reducing overproduction and waste.

3. E-commerce influencing bespoke packaging

The surge in e-commerce continues to influence packaging design. Corrugated packaging in 2025 will prioritise functionality, focusing on easy assembly, durability, and tamper-resistance.

Read about the tamper-proof box we manufactured for LIVVE

Meanwhile, brands are using customisation opportunities to enhance the unboxing experience—a key element in building customer loyalty.

4. Printing on packaging

The need to better connect with customers and stand out from the competition will continue to drive the benefits of printing on packaging.

Read how ASC Direct helped Fat Cow Skincare with branded packaging - Box of the month

Printing on packaging will continue to offer enhanced branding and seasonal references elevating the customer’s unboxing experience. Including QR codes and other links to the brand’s website ensures that corrugated packaging not only protects goods but also serves as a marketing tool.

Packaging designed for improved workflow and automation

With labour shortages and supply chain challenges continuing into 2025, the industry is focusing on designing packaging that is automation friendly. The need to ensure packaging is easy to store and assemble will continue with corrugated solutions being tailored to integrate seamlessly with automated packing lines, ensuring consistency and reducing costs. Modular designs and pre-creased templates are increasingly popular as they simplify operations and improve efficiency.

This year, bespoke packaging is in the perfect position to continue to serve key trends: the increased demand for sustainability; consumer preference for personalised experienced and the ability to provide custom solutions for specific product and production environments.