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More Recyclable Formats

Building a more robust recycling system requires utilizing packaging formats that can navigate the full recycling system and find a path to a viable market post-recycling. Plastic IQ distinguishes two solutions to increase the recyclability of plastic packaging:

  • Switch to more recyclable formats and/or polymers/, such as moving from multi-material to mono-materialitems, shifting to more commonly recyclable polymers, or changing from a small format item (that may be lost in the recycling system) to a larger format item.
  • Design to enhance packaging recyclability (within the same polymer and format). For this solution, see the separate Solutions Database page on “Design to enhance recyclability”.

For rigid packaging, Walmart's Recycling Playbook suggests switching packages made from acrylic, PETG, PVC, PS and multiple materials and focusing on PET, HDPE, LDPE and PP. In addition to switching resin, there are some cases where changing to a different format, such as ensuring the packaging size is not too small to be sorted at materials recycling facilities (MRFs) or switching to a bottle format in the case of PET and HDPE, can also increase recycling acceptability and recovery. Curbside recycling of flexible packaging is currently quite rare and significant investment is needed in the system to make it work.

The table below shows typical recyclability (at scale) of well-designed packaging in each of Plastic IQ's seven packaging types. Using the Plastic IQ Tool enables switching from any "Low" cell to "Medium" or "High", or from any "Medium" cell into "High" (PET/HDPE bottles) to see how switching to more recyclable formats can make a difference.

This lever is likely to be used in conjunction with the enhancing recyclability and substitute levers. For example, in many cases, eliminating certain plastics from a company's packaging portfolio can involve changing labels, shrink sleeves or layers in a cap, which fall under the Enhancing Recyclability lever. Similarly, switching from a PVC plastic blister pack to a paper blister pack falls under the paper substitution lever.

Companies that have joined the US Plastics Pact have committed to ensuring that 100% of their packaging is recyclable, reusable or compostable by 2025. Switching out of the “Hard to Recycle” formats (i.e., other polymer rigids, small packaging formats, non PE film, pouches, other flexibles, and multi material blends) can help meet that target by increasing a package's recovery and recycling rates.

The Walmart Recycling Playbook recommends transitioning out of PS (both rigid and foam). Examples of this type of transition might include converting EPS egg cartons to PET thermoform (3) or molded paper; transitioning yogurt containers and other tubs to PP; moving rigid PS clamshells to PET and PVC blister packs to PET (4) or paperboard boxes.

Mono-material PE film is increasingly available in formats that can, in many cases, provide similar barrier properties to multi-material films, including stand-up pouches (5) and produce bags (6).

The cost of switching packaging format will vary depending on the details of each specific case. Where the costs of moving to a more recyclable format are high, companies may want to evaluate solutions in other levers, for example adopting reusable packaging models or substitution with non-plastic materials.

Increasing the recyclability of a package is likely to lead to GHG emissions reductions at end of life, as recycling a product helps avoid the high emissions associated with virgin, fossil-based plastic. Production-stage emissions do not tend to increase or decrease very much compared to producing non-recyclable formats, as long as a similar weight of plastic material is used. The key is to avoid switching from a light-weight plastic format to a heavy one wherever possible, as this could increase emissions. Companies are encouraged to conduct an individual life-cycle analysis (LCA) to help understand the tradeoffs between production and end of life emissions.

Key Benefits

  • Closing the loop: 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: Increasing the share of recyclable formats in the waste stream and streamlining the diversity of packaging formats are among the most important levers for improving recycling economics and helping to scale up the recycling industry. Many of the benefits of a robust circular economy – reduced resource extraction, reduced GHG emissions, reduced costs, and reduced waste and environmental pollution – can be enabled by shifting to recyclable formats.
  • Responding to consumer expectations: Committing to 100% recyclable, reusable or compostable packaging is becoming the new norm. Companies that put packaging which is not recyclable on the market, in practice potentially risk losing certain groups of consumers.

How to make it work

  • Make the switch: Develop a plan to eliminate non-recyclable formats. For rigids, companies should consider migrating toward PET, HDPE and PP. For flexible packaging, many products may be able to shift to mono-material PE solutions.
  • Consider tradeoffs: Moving from flexible to rigid, or shifting between rigid resins, may enhance recyclability but may also add cost and/or additional weight to a package, potentially also increasing the GHG emissions. It is important to also consider other levers, such as elimination or reuse, if a switch to a more recyclable format will cause negative impacts. Companies are encouraged to better understand their options and potential trade-offs.
  • Share innovations: A unique design in a product category can be challenging for recycling programs to accept and adopt, simply because it is difficult to explain to consumers. By making solutions available to competitors, it may be possible to shift entire product categories, making the change more widespread and acceptable. Such category transitions also require investments in the system to ensure that MRFs will accept the new material.

Enabling system conditions

  • Consistency across product categories: It is important for brands to collaborate to help create clarity for consumers about the recyclability level of packaging for particular products. Aligning formats across brands and companies eases the recycling of the packages by consumers.
  • Broad adoption of recycling labeling: While more and more brands are adopting the use of recyclability labels, it is critically important that consumers can easily identify which packages are recyclable as well as which ones are not – especially as product categories evolve to more uniform material usage.
  • Stronger markets for certain formats including PET thermoforms: While PET bottle grades enjoy very strong markets, PET thermoform markets are still developing although research shows that circular, thermoform-to-thermoform recycling is possible.
  • Greater acceptance for PET thermoforms and PP: While most MRFs accept PET and HDPE bottles, the acceptance for PET thermoforms and PP needs to expand.

Examples and case studies

Sprite bottle from The Coca-Cola Company: Sprite - the soda brand - is transitioning away from their iconic green bottle to a clear bottle to improve its value during recycling. This improves the economics of recycling. In Southeast Asia, clear PET bottles sell for an average of USD 84 per tonne more than coloured bottles (a 35% increase).