70 to 83 percent of Americans are concerned about humanity’s impact on the environment. Consumers increasingly expect industries to share this concern and implement sustainable and circular solutions to mitigate these effects.
The concept of a circular economy is gaining traction in the fight for sustainability in business, offering an alternative to traditional linear models of production and consumption. In a circular economy, waste is minimized and resources are reused, recycled and regenerated.
With Plastic Free July next month, I examine how the packaging industry is evolving to embrace circular economy principles, focusing on innovative designs and practices that promote sustainability and resource efficiency.
The principles of circular economy in packaging design
The core tenet of the circular economy in packaging is to recapture packaging waste and use it as a material to manufacture new packaging, thereby reducing or even eliminating the need for virgin materials.
In a circular economy, the recycled materials continuously feed back into the production cycle, increasing the availability of recycled monomers over time.
The benefit here is twofold: reducing plastic waste in the environment and mitigating the adverse climate effects associated with the manufacture of virgin plastics. This growth in feedstocks and heightened resource efficiency helps reduce costs for all stakeholders and addresses the cost barriers often associated with plastic recycling. Circular packaging design involves several core principles:
Designing for durability
Designing for durability enhances a product's reusability which is central to circularity and means shifting from disposable to durable. To achieve this, packaging should be made with strong, high-quality materials able to withstand repeated use, earning a longer lifespan. Durability also reduces the demand for raw materials and the energy required for production, thereby lowering greenhouse gas emissions.
For example, reusable plastic bottles are reducing the reliance on single-use plastic water bottles, significantly cutting down on plastic waste and minimizing the burden on waste management systems and the environment.
Material innovation
In the packaging industry, the development of biodegradable and home-compostable packaging has revolutionized the vision for the future. However, this progress must be approached with caution.
Questions have been raised about the true compostability and biodegradability of these packaging solutions. Not everyone has access to commercial composting facilities or even a home compost heap. Furthermore, nearly one-third of Americans are unsure how to correctly dispose of compostable packaging and mistakenly place it in the recycling bin.
While innovation is vital, it must also provide a credible circular solution to effectively address the current environmental and climate crisis.
Lifecycle thinking
To truly achieve circularity, lifecycle thinking is essential, ensuring the environmental impact of each stage in the design process is considered. This encompasses everything from raw material extraction, such as the petroleum oils used in virgin plastic production, to disposal.
Optimizing material use from the beginning is crucial, reducing the quantity of materials needed for packaging without compromising functionality. For instance, Amcor successfully reduced the PET required in a 12-ounce bottle by 13 percent while maintaining the necessary strength.
End-of-life management in the product lifecycle demonstrates a business's accountability, taking ownership of the environmental impact their product has after sale. For example, Coca-Cola removed plastic labels from its bottles to enhance the recyclability of the product after use.
Innovations in circular packaging solutions
Traditional packaging is being outgrown by society due to the increasing climate concerns that are influencing consumer choices. In response, innovation is stepping up to meet these new demands.
One notable trend is the rising demand for mono-material packaging, which offers higher recyclability since products are made from a single material. Mondi, for example, was recently praised for their innovative mono-material cheese packaging solution. This design not only keeps cheese as fresh as possible but also prioritizes ease of recyclability for consumers and waste management facilities.
Enzymatic recycling is an exciting novel solution that involves re-engineering a natural enzyme found in leaves to completely break down PET plastics into their original chemical components, the same building blocks used to produce PET initially. This process enhances the circular economy by improving the availability of recycled raw materials, operating at lower temperatures, and using less energy, which ultimately helps reduce plastic waste and carbon emissions.
Lastly, 3D printing enhances the material optimization capabilities of modular packaging by creating custom, form-fitting packaging that fits snuggly around a product. 3D printing also caters to the use of biodegradable and nature-based materials, reducing waste and energy consumption, while championing the use of a more sustainable material and promoting circularity in disposal.
Instead of relying on new raw materials, 3D printing can recycle and repurpose existing plastics, reducing waste.
Challenges and opportunities in adopting circular packaging solutions
The swift adoption of circularity faces several challenges. Firstly, effective recycling relies heavily on proper consumer disposal, an ongoing issue with 76 percent of recycling ending up in general trash in America.
Additionally, sustainable, eco-friendly, and compostable packaging costs more than traditional materials like plastic, cardboard, and paper. This cost disparity makes consumers reluctant or unable to stretch their budgets for sustainable solutions, while businesses must consider economic viability given the increased expenses associated with adopting these environmentally friendly options.
For example, enzymatic recycling will initially be costly, with prices about 60 percent higher. However, as the circular process matures and the availability of recycled monomers increases, costs will gradually decrease. This growth in recycled feedstocks will eventually make the process more economically viable for all stakeholders, including end-consumers, leading to lower prices and more widespread adoption of sustainable packaging solutions.
Lastly, with growing societal pressure for governments to respond to the climate and plastic crises, there are more regulations for businesses to bear in mind. For example, since October 2023, businesses in the US and UK have been subjected to varying degrees of single-use plastic bans. That being said, there is no federal ban on single-use plastics across America, limiting the impact this could have on minimizing plastic waste.
These regulations are a step forward in the fight for future generations but can be challenging for businesses having to navigate new supply chains, costs and administration to ensure they don’t cross regulatory boundaries and risk fines or prosecution.
There is, however, regulatory support available and 20 states have passed laws, along with financial incentives, enabling waste plants to reclassify from advanced recycling facilities to manufacturing plants, providing economic advantages to businesses.
As regulatory support increases and technology advances, more businesses will find it feasible to adopt circular practices, reducing their environmental footprint and fostering a greener industry.
Circular packaging is a promising solution leading to a substantial reduction in waste, lower carbon emissions, and the conservation of resources, contributing to a more sustainable packaging industry overall.
For more information, please visit www.uspackagingandwrapping.com