Welcome to the Solutions Database,
a guide to technologies, strategies, and best practices for reducing plastic waste

Packaging can be minimized while maintaining functionality and user convenience by reducing over-packaging (12). Over-packaging includes unnecessary headspace, overly large packaging, and avoidable components such as caps. In addition to cutting costs and waste, reducing over-packaging is popular with consumers as many people prefer smaller packages and get frustrated when plastic packaging seems unnecessarily wasteful.

Key benefits:

• Developing custom size packaging can reduce over-packaging: Ensure that the shape and size of packaging matches the product in question and avoid excessive packaging material, void fill, or oversized packaging (12). Reducing over-packaging, for example by cutting unnecessary headspace, can lead to less packaging material as well as lower transport costs and greenhouse gas emissions savings (4).
• Packaging reduction can be facilitated by novel packaging and design concepts: Consider switching the packaging type as some packaging concepts, such as vacuum skin packs or folded packs, can reduce the amount of material or packaging volume needed (12). For luxury items packaged in several layers/boxes, these attractive effects can be created using graphics, higher quality print and packaging materials, or point-of-sale displays instead of extra packaging volume (14).

Key watch-outs:

• Make sure barrier properties and other packaging functions can still be met while reducing over-packaging: Over-packaging is defined as packaging that is unnecessary in terms of functionality. For some products, such as yogurt pots, a small headspace may fulfill essential functions for preservation. Effective packaging reduction solutions are those which still fulfill essential functions, such as those related to product protection, machine requirements, or shipping and handling (4)

• Minimize headspace in trays, pots, pouches, or plastic bags, that are often packaged in larger packaging than needed, sometimes to increase the perceived product size. For instance, potato chip packets often double the volume of the product. Minimizing headspace can be especially relevant for e-commerce, where shelf appeal plays little to no role.
• Minimize wrapping volume to the smallest amount needed to protect/hold together the product. This can be done by reducing the layers of wrapping, minimizing the packaging size, or changing the design of multi-wrappings using solutions like multi-pack handles.
• Minimize sealing packaging material by utilizing new sealing approaches that reduce the size of the liner back seal.
• Minimize the size/volume of attachments such as caps, or – ideally – combine them with the main packaging.

Initial guidance on applicability of this solution per plastic type: