As flexible plastic packaging moves closer to mainstream kerbside collection in the UK, the question of whether pouches are recyclable is becoming harder to ignore. The problem is that pouch recyclability is still often discussed in broad terms, as though all pouches behave the same way at end of life. In reality, the answer is far more dependent on structure, finish and fitments and packaging design is increasingly being shaped by the need for simpler, more consistent material streams that can be identified, sorted and reprocessed more effectively to meet the needs of recyclers.
This is one of the reasons mono-material PE and PP structures have gained so much traction in recent years. The logic is straightforward: if material complexity can be reduced without compromising pack performance, the material becomes more valuable and stands a better chance of fitting into a developing recycling system. Even so, recyclability still depends on more than polymer choice alone. Barrier requirements, printing, metallisation, foil layers and rigid attachments such as spouts can all affect how a pouch behaves once it enters a sorting line.
A recent pouch recyclability study by SPS Pouches looks at this issue in more detail and makes the point that the more useful question in 2026 is not simply whether pouches are recyclable, but which pouch structures are most likely to work within the systems that exist now. As part of that work, SPS Pouches partnered with RECOUP to test several pouch constructions at a Materials Recovery Facility (MRF) in Sherbourne.
The strongest result came from an MDOPE with EVOH / LDPE structure, which achieved 20 out of 20 positives at both sort stages and was directed into the films and flexibles stream. That suggests mono-PE solutions may currently offer one of the most credible routes for brands looking to improve pouch sortability.
The testing also highlighted where problems remain. A fully visually metallic PET / Alu / LDPE structure failed outright, reinforcing the point that highly reflective and heavily metallised packs can still create problems for optical sorting systems. A spouted pouch raised a different issue, with the fitment changing how the pack moved through the plant and pushing it into the 3D stream. The article also notes that some mixed laminate structures may still sort into the films and flexibles stream, but that this does not necessarily mean they will produce high-quality recyclate downstream.
That is probably the most useful takeaway. The future of pouch recyclability is unlikely to be decided by one simple claim. It will depend on whether packaging has been designed for the realities of collection, sortation and reprocessing, and whether the material recovered has enough consistency and value to support viable end markets.
For brands wanting a clearer view of which pouch structures are likely to make the most sense for their product can also speak directly with SPS Pouches for practical sustainability advice.