In this interview, Usha Benjamin sits with Patrícia Onishi, Assistant Manager – Packaging Experience, RDD at AIR (Advanced Inhalation Rituals), to discuss her global packaging journey, key sustainability innovations, and the evolving role of women in the industry.
In an industry where performance and sustainability intersect, packaging professionals are being pushed to go beyond materials and processes. Patrícia Onishi is among those contributing to this shift. With experience across Latin America, Europe, and the Middle East, she has worked on packaging solutions ranging from high PCR-content flexible formats to recyclable and paper-based alternatives.
Usha Benjamin: You began your journey in packaging through R&D and have since worked across global markets. How has your career evolved, and what were the key turning points?
Patrícia Onishi: My journey began during my Food Engineering studies when I joined PepsiCo in Brazil as a packaging intern. That experience had a strong influence, exposing me to lab testing, production trials, logistics optimisation, and design development. It built my technical foundation and defined my purpose—to create impact through packaging innovation.
Over time, working across different regions helped me understand how packaging requirements vary and how solutions must be adapted accordingly. Since then, testing and validation have remained central to my work, ensuring that every development performs consistently across markets.
UB: What initially drew you to packaging engineering, and what continues to motivate you today?
PO: It started with an unexpected opportunity. I entered packaging without prior experience, but quickly realised its potential and the breadth of the field.
During a study programme in Europe, I deepened my technical understanding and became certain this was the path I wanted to pursue. What continues to motivate me is the connection between packaging and people—it is the first interaction consumers have with a product, and it directly influences how that product is perceived and experienced.
UB: You’ve led several sustainability-driven initiatives. How do you balance sustainability with performance, cost, and scalability?
PO: Sustainability depends on evaluating the entire process rather than focusing on a single material or stage. We assess the full lifecycle—from raw material sourcing and production to distribution and end-of-life—while building strong business cases to ensure feasibility.
At the same time, rigorous testing is essential to validate performance. The goal is always to balance environmental impact with functionality, cost, and scalability so that solutions can be implemented across multiple markets and production lines.
UB: You’ve worked on several first-of-their-kind innovations. Could you share some examples and challenges?
PO: While working at Johnson & Johnson, we developed flexible packaging with 33% PCR content, which required close collaboration across the value chain and extensive trials.
Incorporating recycled material at this level meant refining raw material formulations, aligning with converters on processing conditions, and ensuring consistent quality during extrusion and filling. Another project at Johnson & Johnson involved paper-based packaging with coatings, where the challenge was balancing barrier performance with production efficiency and adapting high-speed lines originally designed for plastic materials.
At Himalaya, we introduced 100% recycled FSC-certified cartons and recyclable tubes despite supplier and material limitations. This required adjustments in machinery, validation processes, and quality expectations, particularly for premium products.
Across all these projects, collaboration across teams and continuous testing were essential to achieving reliable and scalable outcomes.
UB: How do packaging requirements differ across regions?
PO: Regulations, supplier ecosystems, and consumer expectations vary significantly from region to region. Product formulations also differ—for example, thicker creams in Europe require different dispensing systems compared to more fluid products in LATAM, which increases the risk of leakage if not properly designed.
These variations add complexity, but they also create opportunities for innovation by pushing teams to develop adaptable and robust packaging solutions.
UB: How important is packaging in shaping consumer perception?
PO: Packaging is no longer just functional—it plays a key role in the overall product experience. It shapes first impressions, influences how consumers interact with the product, and can add perceived value, especially in premium categories.
Designing packaging that delivers both a strong user experience and recyclability is becoming increasingly important as brands respond to both consumer expectations and sustainability requirements.
UB: What materials or technologies will drive circular packaging?
PO: PCR materials will continue to grow as processing technologies improve, enabling higher-quality recycled content across more applications.
Alongside this, mono-material flexible structures are evolving, helping replace complex laminates with more recyclable alternatives. Paper-based solutions are also advancing, particularly with improved barrier coatings.
At the same time, renewable materials are emerging, and regulatory frameworks are accelerating the transition toward fully recyclable packaging systems.
UB: How has e-commerce changed packaging design?
PO: E-commerce has introduced additional complexity in logistics, requiring packaging to withstand handling, transportation, and direct-to-consumer delivery conditions. This has increased the need for durability, validation, and testing.
At the same time, unboxing and the overall consumer experience have become more important, as packaging now plays a direct role in brand perception at the point of delivery.
UB: What does leadership mean to you?
PO: Leadership is about inspiring and empowering others while creating an environment built on trust. It involves listening, supporting growth, and helping individuals define their own paths.
Through mentoring, I focus on building confidence and enabling people to develop both technically and professionally.
UB: What challenges do women still face in the industry?
PO: Representation in technical roles remains relatively low, and in many situations I have been the only woman in such environments. However, I believe diversity strengthens teams, improves collaboration, and leads to better outcomes.
Increasing participation and creating more opportunities for women will be important for the industry’s future.
UB: How do you build high-performing teams?
PO: It starts with passion, trust, and mutual respect. When people feel valued and supported, they are more engaged and collaborative.
Building strong connections within the team helps create an environment where individuals can perform at their best and contribute effectively to shared goals.
UB: What do industry recognitions mean to you?
PO: Awards reflect teamwork and collective effort. They recognise the contributions of multiple teams involved in a project and help reinforce progress.
They also motivate teams and encourage further innovation by building confidence in what has been achieved.
UB: What advice would you give to young professionals?
PO: Stay curious, keep learning, and don’t wait until you feel completely ready. It is important to understand both technical aspects and consumer perspectives while also measuring your impact.
Being prepared, adaptable, and open to new experiences will help you grow and create meaningful contributions in the industry.