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

Choose your solution

eliminate

Eliminate plastic
minimize

Minimize plastic
reuse

Reuse models
paper

Paper
compostable

Compostable
glass

Glass
metal

Metal
more-recyclable

More recyclable formats
enhance-recyclability

Enhance recyclability
biobased

Bio-based content
mechanically-recycled

Mechanically recycled content
chemically-recycled

Chemically recycled content

Enhance Recyclability

Designing packaging to be compatible with recycling is essential for keeping plastic packaging materials in the circular economy. Plastic IQ distinguishes two solutions that can increase the recyclability of packaging:

  • Switch to more recyclable formats and/or polymers/, such as by moving from multi-material to mono-material items, shifting to more commonly recyclable polymers, or shifting from a small format item to a larger format item. For this solution, see the separate Solutions Database page on “Switch to more recyclable formats”.
  • Design to enhance packaging recyclability (within the same polymer and format), by ensuring packages comply with “APR preferred” guidelines. For many packages, there are often additional modifications that can help further enhance recyclability, the challenge is to design and implement them.

Even seemingly small features can be detrimental to recyclability or even make a package incompatible for recycling all together. Components like labels, adhesives, and fillers can all impact the ultimate outcome from recycling. Designing to enhance recyclability can increase both the process yield and value of recycled plastic (1). It can also determine whether a package will be recycled into a similar application/material or downcycled into a lower quality plastic/application, losing value for the economy.

The Association for Plastics Recyclers (APR) has developed thorough design guidance and test protocols to help packaging designers enhance the recyclability of plastic packages. The APR Design® Guides are organized by resin types (PET, HDPE, PP, PE film, PS/EPS, PLA and PVC) and include common packaging components (labels, inks, adhesives, closures, dispensers, etc.). All APR protocols are publicly available on the APR website and can help designers determine if their package is “preferred” for recycling, has features detrimental to recycling, or is non-recyclable (2).

APR provides protocols for testing and successful recyclable innovations may be eligible for one of the APR Recognition Programs. Designers can also access training and guidance through the APR Design® for Plastics Recyclability Training Program.

In addition to the APR Design Guides, there are additional resources available that can help companies further assess recyclability. Walmart developed a Sustainable Packaging Playbook to provide suppliers guidance on improving the recyclability and sustainability of their packaging portfolio. It summarizes many of the details of the APR Design Guides for many common packages, and helps companies identify which packages can be converted to a more recyclable format and how to enhance the recyclability of packages (4).

As part of the Ellen Macarthur Foundation’s Global Commitment, as well as the US Plastics Pact, signatory companies commit to make 100% of their plastic packaging recyclable, reusable or compostable by 2025. To make sure all their packaging can navigate the recycling system and return the highest value, companies should not just aim to use materials that are accepted but strive to achieve a “preferred” recycling status in accordance with the APR protocols.

Every company should have process to review recyclability of packaging and to advance innovations to help their packaging be fully recyclable. For example, Johnson & Johnson recently demonstrated this type of improvement by switching from pumps containing detrimental metal springs to flip-top caps on small HDPE bottles of liquid soaps. They have pledged to continue to work on designing a recyclable pump for larger sizes with the goal of introducing recyclable pumps within a few years (3).

The cost effects of these changes to enhance recyclability can vary significantly and are hard to quantify. In some cases, there are potential cost savings from removing elements that negatively affect recyclability (e.g., pigments). In other cases, improving recyclability may add costs. In addition, research and innovation may require an initial investment but end up leading to lower costs in the long-term. Short term costs to improve recyclability may lead to lower costs later for recovery and in the creation of PCR.

Enhancing recyclability allows more material to be recycled, for example by reducing loss rates and increasing material quality both at the MRF and at the recycler. This keeps plastic waste out of incinerators and landfills and replaces virgin plastic production – and so reduces overall GHG emissions. The Plastic IQ model splits the climate benefits of recycled content between packages that use recycled content and those that are recyclable and therefore provide recycled material.

Key Benefits

  • Creating feedstock for recycled content: Having sufficient quantity and quality of recyclable feedstock is a prerequisite for being able to purchase a large quantity of high quality recycled content. Companies that have committed to a high share of recycled content in their products depend on the availability of sufficient recyclable packaging to meet this commitment.
  • Enabling the circular economy: Enhancing product recyclability can enable many of the benefits of a robust circular economy, including reduced resource extraction, reduced GHG emissions, reduced costs, and reduced waste and environmental pollution.
  • Reduced risk: Retailers are placing increased scrutiny on the recyclability of packaging in their stores. Tightening regulatory environment in many countries indicate greater pressure on non-recyclable packaging, and enhancing recyclability now may reduce the risk of future end of life business costs.

How to make it work

  • Stress-test the recyclability of your packaging: Review the recyclability of current packaging against guidelines such as the APR Design® Guide or Walmart's Sustainable Packaging Playbook, and incorporate design principles into company processes for all new packaging designs and approvals. If a package does not meet the APR preferred status, identify the elements that are holding it back and develop a plan to address them.
  • Work with your suppliers: Suppliers are rapidly innovating and working to create new solutions for more sustainable packaging. There are constant advancements in barriers, inks, and adhesives, for example. Consider working with your suppliers to ensure their products meet all of the APR Design Guide criteria.
  • Inspire innovation: Consider supporting open design challenges to bring new ideas to the table or implement existing ideas to new products/applications. Include a comprehensive review of recyclability in your new package design or your package change process.
  • Celebrate improvements: Leverage the storytelling capabilities of your marketing department to communicate changes to your customers. Improvements in recyclability can be signaled with on pack messaging, as well as in other channels. Seek communications methods that will resonate with your consumers.

Enabling system conditions

  • Better materials: Improvements in materials can lead to more APR preferred components for package designers to work with to improve the recyclability of products.
  • Better sorting technology: Advancements in sorting at MRFs can help segregate packages that are currently seen as detrimental, leading to higher quality bales of the preferred materials.
  • Policy changes: Policy interventions that promote the use and increase the value of recycled polymers can incentivize producers to develop products with end-of-use considerations.
  • Industry collaboration: Industry players can collaborate to:
    1. develop new polymer production and packaging designs in coordination with recycling and sorting technology companies;
    2. co-develop re-extrudable inks and new printing processes with ink manufacturers to enable brand differentiation without the contamination associated with inks, additives, and mixed polymer use; and
    3. streamline materials and packaging formats across companies. A prime example of industry collaboration was the switch from PETG to extrudable PET (EPET) when PETG was identified as a contaminant in the recycling stream, causing many companies to innovate and create EPET as a prime alternative, especially in clear bottles with handles. (5)

Examples and case studies

References and Further Reading

  1. The New Plastics Economy (2017), World Economic Forum, Ellen MacArthur Foundation, and McKinsey & Co.
  2. APR Design Guides, The Association of Plastic Recyclers
  3. J&J overhauls pumps to aid recycling (2021), Sustainable Brands
  4. The Recycling Playbook (2021), Walmart Inc.
  5. Why Blow Molders are Switching to EPET (2019), Plastics Technology