Toppan has developed a paper-based packaging solution for trading cards that aims to eliminate the use of plastic while maintaining the functionality and appearance required by the rapidly growing collectibles market.
The Japan-based printing and packaging company said its new pillow-style packaging achieves 98% light shielding, overcoming one of the key barriers to replacing conventional plastic packs with paper. Traditional paper materials have generally been unsuitable for trading cards because the contents can often be seen through the packaging.
According to Toppan, the new design prevents consumers from identifying cards before opening the pack, helping to deter so-called “pack searching,” a practice used to locate rare cards without purchasing multiple packs. The company also said the packaging retains a metallic appearance and premium visual quality while reducing the wrinkling often associated with paper pouches.
The development comes as trading card manufacturers face increasing pressure to reduce the environmental impact of packaging. Toppan noted that the trading card market in Japan continues to expand, supported by collaborations with sectors including apparel and hospitality, while sustainability requirements and packaging regulations are accelerating the shift away from plastic materials.
“Leveraging its extensive expertise in paper-based packaging development and production, Toppan has selected the ideal material and developed dedicated pouch-making equipment,” the company said. “Through these efforts, Toppan has overcome the inherent transparency of paper, minimized wrinkling, and established a stable supply system for high-quality paper-based pillow packaging.”
The company said conventional trading card packaging typically combines plastic materials for mechanical strength with adhesive sealant layers. Its new alternative uses a paper substrate combined with a heat-seal coating layer to achieve the necessary packaging performance.
In addition to reducing plastic content, the packaging exceeds the threshold required for Japan’s “Paper Mark” recycling symbol, with paper accounting for more than 51% of the package weight. Toppan said this will allow brand owners to communicate their sustainability credentials more clearly to consumers.
Sample quantities of the packaging are available to trading card manufacturers worldwide from June 2026, with commercial-scale production scheduled to begin this autumn.
The launch forms part of Toppan’s broader push into more sustainable packaging solutions. Recent initiatives include a collaboration with PureCycle Technologies to develop flexible films and thermoformed packaging containing recycled content, as well as investments in film manufacturing capacity through a hybrid BOPP and BOPE production line in India and the acquisition of a majority stake in Italian BOPP film producer Irplast.
