Plastic packaging is an ideal packaging solution for food—it delivers unmatched performance for food protection, increasing shelf life and preventing food waste across versatile packaging formats. But to continue to allow plastics to be the material of choice, we need to also address plastic waste by expanding circular practices that keep valuable materials out of landfills and the environment.
Extended producer responsibility (EPR) legislation, supported by a growing consumer awareness of environmental impact and sustainability concerns, is shifting the conversation surrounding plastic recycling. Rapidly advancing technologies are making it possible for post-consumer recycled (PCR) plastics to meet the performance and compliance requirements of even the most stringent end use applications, including food-contact compliant packaging.
Although recycling infrastructure and logistics still require further investment and development, the technological capabilities to produce high-quality recycled plastic exist today. Now, the remaining and developing ingredient to building a more circular economy for plastics is proactive commitment from brands and retailers to design packaging for recyclability and incorporate PCR content into new packaging.
Designing for Recyclability is a Top Priority
In packaging design, creating plastic structures that are compatible with existing recycling streams has become the top priority for many consumer packaged goods (CPG) companies. Survey data from PMMI’s “The New Material World: Packaging’s Path Toward Sustainability” report show that 55 percent of respondents are extremely likely to increase their use of recyclable packaging materials within the next five years, up 10 percent from the last survey conducted in 2022. State and regional EPR policies are influencing companies’ packaging strategies in this space, for example with high fees proposed for packaging formats that are not considered widely recyclable.
Impact of EPR Policies and Recycled Content Mandates
EPR legislation is gaining momentum throughout North America and Europe. These laws aim to shift the cost and operation of waste management responsibilities to producers of the package, most often recognized as the brand owner or retailer for private label products. As compliance and enforcement structures take shape, fee structures and penalties, including eco-modulation, must be properly designed to incentivize recyclable packaging and the use of PCR materials, recognizing the higher cost of these solutions compared to traditional packaging. Alongside EPR policy, we are also seeing the implementation of recycled content mandates at a state level to drive end market demand for PCR – this is one of the most effective tools in moving from an optional framework to one of legislated action. Again, given the higher cost of recycled polyethylene packaging, this is essential to drive the systemic change needed to transform the plastics value chain and to drive continued investment in recycling infrastructure.
Effective policies and legislation must focus on making it more difficult for companies to opt out of rethinking their use of plastic packaging by simply paying a fee. Targets for recyclable packaging and PCR content mandates should recognize market realities, such as the strict regulatory requirements for food and medical packaging, but also explicitly work to build robust end markets that support investment in recycling infrastructure and stable demand for PCR materials. Paying penalties for traditional packaging formats that are neither recyclable nor contain recycled content cannot be a substitute for the hard work needed to enable systemic changes that will ensure plastic products stay in a circular economy.
Keeping Plastics the Top Choice
Changing how plastics are managed through its lifecycle is integral to maintaining food safety, freshness, and quality while also keeping plastic in the economy at its highest value. Plastics provide the necessary barrier properties and durability to protect and transport food across complex supply chains. These attributes minimize food waste, which would otherwise end up in landfills and contribute to greenhouse gas emissions.
Research from the Sustainable Packaging Coalition reinforces the importance of considering packaging’s full lifecycle impact, particularly in relation to food waste. On average, packaging accounts for about 3 percent of the climate impact of packaged food. Optimized packaging designs can help reduce food waste and lower overall carbon footprints. Studies show that consumers want packaging features that help them waste less food, such as resealable zippers or smaller individual portions.
The environmental upside of effective packaging is significant. Data from the ReFED Insights Engine, a nonprofit focused on reducing food waste, found that improving food packaging to reduce spoilage and unused product could cut carbon dioxide equivalent emissions by 870,000 metric tons, save more than 49 billion tons of water, and divert 153,000 tons of food waste from landfills each year.
Packaging research highlights the importance of understanding lifecycle tradeoffs when evaluating different materials. Switching away from plastic without considering performance and environmental implications can have unintended consequences, including increased resource use during production, heavier packaging that requires more energy to transport, or reduced shelf life that increases food waste. By capitalizing on the high-performance capabilities of plastics, thoughtful packaging designs can deliver convenience and waste reduction benefits, creating value for brands and consumers.
The Realities of Recycled Plastics
In addition to the benefits plastic offers for food packaging, advances in mechanical recycling are enabling more plastic structures to be recycled. Technologies such as AI-powered material detection and sortation are improving recovery rates and PCR quality. State of the art mechanical recycling processes, when combined with strict sourcing and quality controls, are now capable of producing food contact compliant PCR resin. This has opened the aperture on ways to deliver recycled polyethylene packaging that resonates with consumers, as most prioritize inclusion of recycled content when they understand that this drives more collection and ultimately more recycling of the packaging they know and use every day.
Packaging design is also evolving to support recyclability at scale. Mono-material flexible packaging allows more structures to flow through recycling systems rather than being rejected like mixed-material laminates that are not recyclable. New resin grades, sealants, and machine orientation support all-polyethylene (PE) pouches and bags that meet store drop-off recycling program requirements without sacrificing package weight or performance. Mono-material packaging can help improve feedstock quality and collection opportunities over time.
Despite this progress, access to PCR materials suitable for food packaging remains a challenge today. Variability in bale quality and processing complexity limits supply availability and contract development. For packaging users, waiting for the market to solve these problems is not an option. The plastics industry must come together as a whole to build a viable, profitable circular economic model. By using recycled content and making packaging recyclable, brands and retailers are demonstrating action to support investment in recycling infrastructure and reshaping how plastic waste is viewed.
How to Shift From Linear to Circular
Shifting from a linear to a circular system will require commitment. Brands and retailers play a critical role in leading the development of closed-loop solutions. This involves examining plastic waste management practices at distribution centers, warehouses, and retail locations to identify opportunities for collection. Designing pathways for materials used in facilities to be collected, reprocessed, and reused within localized supply chains is essential, and we are seeing this manifest in increased oversight of PCR supply chains through third part certification programs
For food packaging, this approach also requires operational adjustments to maintain chain of custody and ensure compliance. Adopting these practices will require time and coordination, but they are necessary for responsible plastics management.
Companies must also prioritize purchasing recycled plastic. Creating demand for PCR materials is necessary to stabilize markets and encourage investment in recycling programs and infrastructure. Long-term supply agreements can help reduce pricing volatility and provide greater security for buyers and recyclers alike.
Prioritizing regulatory compliance is critical when sourcing PCR, particularly for food-contact plastic. In the U.S., recycled materials must meet the same requirements as virgin plastic for food applications. Recyclers can submit their process for review by the U.S. Food and Drug Administration (FDA), and if satisfied, the FDA will issue a Letter of Non-Objection (LNO). The LNO will state that the recycling process, given a suitable feedstock, has the capability of producing recycled material for food contact applications under specific conditions of use (for example, Conditions E through G would indicate restrictions to a certain temperature range).
While an LNO is valuable, it should only be used as a starting point for companies exploring PCR materials. An LNO demonstrates that a recycling process has been reviewed for its effectiveness in removing contaminants, but variations can still exist in the quality and performance of recycled resins produced under different systems. Brand owners, converters, and packaging designers have an obligation to understand what an LNO does and does not mean and continue to evaluate materials based on real-world performance requirements.
With their demanding performance and regulatory requirements, food applications are driving advances in plastic and recycling technologies. Ultimately, the entire value chain has an important part to play in expanding the use of recycled plastics and recyclable packaging. Shifting our collaboration mindset from linear to circular – by including all parties at the table – will accelerate packaging innovation and help build a more robust supply chain. Ultimately, we want to keep plastics as the top choice for food packaging, and we can support this by delivering recycled polyethylene plastic food packaging that contributes to lasting changes in how plastics are managed throughout their lifecycle.
