Pan masala and gutka packaging in India: why the industry is going plastic-free

For decades the pan masala sachet was a showcase of flexible packaging: bright gravure print, a metallised layer for shine and barrier, and a laminate that kept the product fresh for months. That pack is now being regulated out of existence. If you make, pack or supply this category, here is the current position and where packaging is heading.

What the rules say today

Plastic Waste Management Rules, 2016

Rule 4 of the Plastic Waste Management (PWM) Rules has long prohibited plastic sachets for storing, packing or selling gutka, tobacco and pan masala, and bars plastic material in any form in packaging for these products. In 2016 the Environment Ministry ordered major manufacturers to stop using plastic packaging, following earlier Supreme Court directions.

Enforcement has tightened since. In July 2025 the National Green Tribunal issued notices to gutka and pan masala units over alleged violations, pointing to Central Pollution Control Board closure orders for 25 units that had not been fully carried out.

FSSAI Packaging Amendment Regulations, 2026

On top of the PWM Rules, FSSAI has now set specific packaging requirements for pan masala. After a draft in April 2026, the Food Safety and Standards (Packaging) Amendment Regulations, 2026 were published in the Gazette on 10 August 2026. They add pan masala to Schedule IV of the 2018 Packaging Regulations and allow only:

• paper, paperboard, cellulose or other naturally derived materials, provided they are free from any plastic;
• tin containers; and
• glass containers.

Plastics such as PE, PP, polyester and PVC, other synthetic polymers and laminates are excluded, and so are aluminium foil and metallised layers, even as an inner layer of a paper pack.

Gutka itself, a mix of tobacco and pan masala, is also prohibited as a food product in most states, so the market that remains is pan masala and separately sold chewing tobacco.

Five packaging trends in this category

1. Paper and cellulose replace laminates

The most visible shift is from plastic-metallised laminates to paper-based sachets and pouches. Brands are testing coated papers, glassine-type papers and cellulose films to recover some of the moisture and aroma barrier that metallised film used to provide.

2. Barrier from coatings, not layers

Because aluminium foil and plastic layers are out, barrier has to come from the paper itself or from compliant coatings. Every coating needs to be checked against the "free from any plastic" wording, so specifications and supplier declarations matter more than ever.

3. Tins and glass for premium packs

Larger and premium packs are moving to tin and glass, which are explicitly permitted and offer a strong barrier. The trade-off is cost, weight and the loss of the low-price single-serve format.

4. Shelf life and sealing trials before launch

Paper behaves very differently on high-speed form-fill-seal lines. Expect more machine trials, more attention to heat-seal and cold-seal options, and shorter shelf-life claims until data supports longer ones.

5. Paper trails for compliance

Brand owners now ask packaging suppliers for material declarations and test reports with every change. Under the general 2018 Packaging Regulations, food-contact packaging also needs a certificate of conformity from an NABL-accredited laboratory.

What this means for brands

If your packs still contain plastic, foil or metallised layers, the safest course is to start your transition now and get legal advice on your specific products. Treat old artwork and old structures as obsolete, and plan for a period of trials as you move to paper-based formats.

How we can help

Active Printpack can print plastic-free, paper-based packaging and help you run machine and shelf-life trials. Tell us about your product and current pack, and we will discuss compliant options.

This article is general information, not legal advice. Check the current notifications with your legal adviser before changing packaging.