Tissue Basis Weight and Its Impact on Packaging and Performance
Tissue basis weight is one of the most fundamental yet frequently misunderstood measurements in the production and packaging of tissue paper products. Defined as the weight of a square metre of tissue paper (expressed in grams per square metre, or GSM), it directly affects how tissue performs, how it is handled by machines and how it is perceived by consumers. Whether for toilet rolls, kitchen towels, napkins or facial tissues, basis weight plays a critical role in balancing cost, strength, softness and packaging efficiency.
Why Basis Weight Matters in Tissue Production
Basis weight is a design parameter. A small change in GSM can dramatically influence the feel, bulk and strength of the final product. Heavier tissue typically means a denser, more absorbent sheet, suitable for kitchen towels or multi-ply toilet paper. Lighter grades offer softness and pliability, which are important in facial tissues and luxury napkins.
Tissue paper is inherently low-density and fibrous. This makes accurate basis weight control critical for consistent converting performance. If GSM varies too much between rolls or batches, it can cause jams, uneven folding or cutting issues during high-speed packaging operations. As such, manufacturers implement tight tolerances on GSM and invest in real-time measuring systems to track basis weight during production.
Implications for Packaging Line Performance
Packaging machines, especially automatic cartoners, must adapt to a wide range of basis weights. Higher GSM tissue generally results in thicker rolls or stacks, which alters pack height and compression characteristics. This impacts everything from feeding consistency and alignment to sealing and stacking.
For example, two-ply toilet rolls with a GSM of 16 per ply may behave very differently on the same line as three-ply rolls with a 13 GSM sheet. The stiffer, thicker product may require slower infeed speeds or modified compression zones. Facial tissue with a GSM of 12 may allow for tighter interfolding and lower packaging volume per unit.
The goal is not simply to maximise GSM, but to optimise it for the use case. This is where experienced packaging engineers and converters add real value; ensuring that the basis weight selected supports not just product function but also machine compatibility, material yield and palletisation efficiency.
Consumer Perception and Regulatory Considerations
Consumers rarely understand the term GSM, but they do recognise the attributes it affects. When people describe tissue as feeling "cheap", "thin", "strong" or "luxurious", they are often referring; knowingly or not; to basis weight and how it translates into bulk, softness and wet strength.
Some retailers and manufacturers promote higher GSM values as a sign of quality, while others aim for lower GSMs paired with ply count or embossing to deliver cost-effective performance. In both approaches, consistent basis weight ensures that pack contents match what’s promised on the label.
In some jurisdictions, basis weight also intersects with labelling regulations, particularly where declarations of sheet count, ply count or roll length are required. Inaccurate basis weight can affect these calculations and result in packaging compliance issues.
Trends in Lightweighting and Sustainability
A key trend in recent years is lightweighting; reducing GSM while maintaining performance. This allows tissue brands to reduce fibre usage, lower shipping weight and increase the number of units per pallet, contributing to both cost savings and carbon reduction.
However, lightweighting comes with risks. Too low a basis weight can cause tear-outs, dusting or poor consumer acceptance. As such, it must be managed carefully through pulp blending, chemical enhancement (e.g. wet strength resins) and packaging system calibration.
Lightweighting also has implications for secondary packaging. Rolls with lower GSMs may compress more easily, affecting bundle stability and requiring revised shrink film or carton dimensions.
How We Can Help
Tissue basis weight is a critical factor in how tissue products are manufactured, packaged and perceived. It influences product quality, machine behaviour, logistics and sustainability outcomes. Getting it right means balancing many variables, including raw material costs, consumer preferences and equipment performance. At Jacob White Packaging, we work with clients across the tissue sector who are facing these exact challenges. Whether you're scaling production or looking to optimise packaging performance, our team brings experience and proven solutions to every project. Get in touch to find out how we may be able to help.
