Sustainable Packaging & Recycling
Sustainability is an important consideration in packaging design. But sustainable packaging isn't simply about choosing glass instead of plastic or using a certain type of resin.
A packaging solution must protect the product, perform as intended, and meet the customer's requirements. Sustainability can be evaluated alongside those needs.
In this lesson, we'll introduce some of the most common sustainability terms and packaging options.
Sustainable packaging focuses on reducing environmental impacts while maintaining the protection and performance required for the product.
Depending on the application, this may involve using recycled content, reducing material use, improving recyclability, considering reuse, or reviewing the overall packaging design.
There is no single packaging material or approach that is automatically best for every application.
Reduce
Look for opportunities to use materials and resources more efficiently without compromising package performance.
Reuse
Consider whether packaging can be designed for multiple uses, when appropriate for the product and application.
Recycle
Consider the materials and design features that may help packaging enter suitable recycling systems.
Understanding PCR
One term you'll hear frequently in sustainable packaging conversations is PCR.
PCR stands for Post-Consumer Recycled.
PCR material is recovered from products that have already been used by consumers or other end users and collected for recycling.
Reprocessed PCR plastic may be used to manufacture new packaging, when appropriate for the application.
How PCR Can Become New Packaging
Used plastic packaging is collected.
Materials are separated, cleaned, and processed.
Suitable recovered material is converted into resin for new manufacturing.
Recycled resin may be incorporated into a new bottle or container.
Example: 25% PCR Content
Suppose a bottle is specified to contain 25% PCR plastic by weight.
That means approximately one-quarter of the bottle's plastic material, by weight, comes from post-consumer recycled sources.
The remaining content could include virgin resin or other specified materials, depending on the formulation.
The actual percentage and material composition should be confirmed with the manufacturer.
Recycled content describes material that has already been recovered and reused in a new product.
Recyclability describes whether a package can be collected and processed through an appropriate recycling system.
These are two different packaging characteristics.
Understanding Resin Identification Codes
Many plastic bottles and containers display a number associated with the type of plastic resin used.
These are called Resin Identification Codes (RICs). The numbers commonly range from 1 through 7.
Resin identification codes help identify plastic types.
The presence of a resin number does not automatically mean the container can be recycled in a particular community.
Recycling acceptance varies by program, material, packaging format, and other factors.
These numbered symbols are simplified instructional illustrations, not official recyclability certifications.
What Makes Packaging Recyclable?
Whether a package is recyclable involves more than identifying the plastic material.
Material & Design
The package must be suitable for recycling through an appropriate recovery and processing system.
Collection Access
Consumers or businesses need access to a recycling program that accepts the package.
Processing & Recovery
The packaging must be able to move through the applicable sorting and recycling process.
Why Do Caps and Labels Matter?
A bottle is often more than a single plastic material.
It may also include a cap, pump, label, adhesive, colorant, or other component.
These details can affect how the complete package is collected, sorted, and processed.
A bottle made from a commonly recycled resin is not automatically recyclable as a complete package.
Recyclable vs. Recycled Content
| Term | What It Means |
|---|---|
| Recycled Content | Material recovered from a previous use or manufacturing waste stream and incorporated into a new product. |
| PCR Content | Recycled material recovered after use by consumers or other end users. |
| Recyclable | Capable of being collected, recovered, and processed through an established recycling program. |
| Resin Code | A number that identifies the plastic resin category, not a guarantee of recycling. |
A bottle containing PCR plastic may or may not be recyclable in a given recycling system.
Likewise, a bottle made entirely from virgin plastic may still be designed for recycling.
Recycled content and recyclability must be evaluated separately.
What Is Packaging Lightweighting?
Another approach to sustainable packaging involves reducing the amount of material used to manufacture a container.
Lightweighting is the process of reducing a package's weight while maintaining the performance required for its intended use.
It may involve changes to container design, material distribution, or other manufacturing considerations.
Example: Reducing Bottle Weight
Imagine an existing bottle weighs 35 grams.
Through an approved redesign, its weight is reduced to 30 grams.
This represents approximately a 14% reduction in container material by weight.
However, the lighter design must still be tested to ensure it meets requirements for strength, filling, storage, transportation, and product use.
Material Efficiency
A successful lightweighting project can reduce raw material use per container.
Packaging Performance
Weight reduction must be balanced with strength, durability, and other requirements.
Overall Impact
Environmental benefits should be evaluated in the context of actual material savings and package performance.
Recycled content, lightweighting, design for recycling, and reusable packaging are different strategies.
A suitable solution depends on the product, performance requirements, customer goals, and supply chain.
Real-World Example: A Customer Wants a More Sustainable Bottle
A personal care company asks Empire EMCO for a more sustainable version of its existing packaging.
Rather than immediately recommending one material, useful questions include:
- Is the priority increasing recycled content?
- Does the customer want to reduce overall material usage?
- Is improved recyclability a primary goal?
- Must the new package work with existing filling equipment and closures?
- Are there specific appearance, performance, or regulatory requirements?
These questions help identify the sustainability options worth evaluating.
What You've Learned
Sustainable packaging involves practical decisions about materials, design, performance, and end-of-life considerations.
Six Things to Remember
- Sustainable packaging seeks to reduce environmental impacts while meeting product performance requirements.
- PCR stands for Post-Consumer Recycled.
- PCR content and recyclability are different characteristics.
- Resin identification codes identify plastic categories, not guaranteed recyclability.
- Closures, labels, and other components can affect recycling compatibility.
- Lightweighting reduces material use only when required performance can be maintained.
In Lesson 8, we'll explain why a bottle or closure that works for one product may not work for another.
We'll introduce formulation compatibility, filling conditions, package testing, and the questions that help identify the right solution.