How to Transition from Virgin to Recycled Plastics in Packaging

Recent news reports highlight the critical importance of plastic recycling in addressing the escalating waste crisis around the world. The overwhelming presence of plastic in landfills and waste collection facilities poses a significant challenge. 

Despite this, manufacturers continue to produce new plastics from virgin plastic resins, exacerbating the issue. To tackle this problem effectively, it is essential for manufacturers to adopt more sustainable practices, particularly in packaging, where change is most needed. Transitioning from virgin plastics to recycled materials can have a major positive impact. 

Virgin vs. Recycled Plastics for Packaging

Virgin plastics are made from new raw materials, such as natural gas or crude oil, that have never been used before to create packaging. This production process has a more consequential negative impact on the environment compared to packaging made from recycled materials, which are created from previously used plastic products that are broken down and repurposed. 

Since the 1950s, plastic has become the preferred choice for packaging due to its low cost and lightweight properties. However, the ongoing reliance on virgin plastics has led to a substantial accumulation of plastic waste in landfills. In 2018, for instance, plastic packaging accounted for 14.5 million tons of waste in the United States, according to the EPA. 

Rather than eliminating plastics entirely, which could minimize the waste issue but lead to another set of problems, including an increase in damaged products or forcing manufacturers to purchase higher-cost plastic alternatives, the solution is to shift towards using post-consumer recycled (PCR) plastics. 

By utilizing previously used plastic, we can keep it out of landfills and waterways. Integrating packaging into the circular economy by empowering both consumers and manufacturers to transform waste plastic into new packaging can help address the plastic pollution crisis effectively.

Benefits of Recycled Plastic Packaging for Your Business

Transitioning from virgin plastic packaging to recycled options offers several advantages for companies. First, this switch allows you to continue using plastic bottles, bags, and containers while significantly reducing your carbon footprint. Incorporating recycled plastic packaging can help you achieve sustainability goals and requirements. By making this change, you’re actively contributing to the preservation of your local community and its environment for future generations.

Second, today’s consumers prefer to support companies that take environmental concerns seriously. As a result, they are more inclined to purchase products that prominently feature recycled materials as well as recyclable materials, including clear messaging about how to responsibly dispose of the packaging when it’s done. This not only benefits the planet but also enhances your company’s reputation among potential customers. 

Lastly, embracing sustainable practices can lead to increased revenue. Customers who prioritize environmental responsibility are likely to choose your company over competitors, ultimately boosting your bottom line. 

How to Make the Shift to Recycled Plastic Packaging

If you currently depend on virgin plastic materials for your packaging needs, switching to more sustainable options can seem expensive and daunting. You may be wondering which kinds of plastic are best for recycling or what PCR packaging entails. Below, you’ll find a comprehensive and actionable guide to help you make this transition successfully, complete with specific details for successful implementation.

Step 1: Assess Your Current Use of Virgin Plastics

Before doing anything else, you must take time to evaluate your current packaging materials. Determine who your key suppliers are, whether they rely on new products or recycled products, and if the answer is both, what percentage of each they use. You may find that you already use a significant amount of recycled plastics, or you may find that it’s time to improve the sustainability of your packaging strategy.

Step 2: Define Clear Sustainability Goals

Start by outlining your sustainability goals, ensuring they are specific and measurable. Instead of vague statements about improving sustainability, set clear targets that can be quantified. This approach enables effective tracking of progress and creates a structured path for transitioning towards more sustainable practices.

As you establish clear sustainability goals, consider current national and local initiatives and packaging regulations, and align your goals with them. The EPA’s “National Strategy to Prevent Plastic Pollution” is a good starting point. Its aim is to eliminate the release of plastic waste by 2040 through the creation of a truly circular economy. It highlights the importance of improved water management, reduced waste generation, and innovative material and product design as ways to achieve this. Creating goals that align with such documents will further support your commitment to sustainability.

Step 3: Research and Select Suitable Recycled Plastics

When considering your packaging needs, take the time to explore the different products and materials available. Understanding recycle numbers and the different types of plastics is a good starting point. Here are some options: 

• Polyethylene Terephthalate (PET): This strong, thermostable plastic is ideal for personal care products, food containers, and beverage bottles. PET is well-suited for everyday consumer needs and is also very easy to recycle.
• High-Density Polyethylene (HDPE): HDPE is commonly used in milk jugs and detergent bottles due to its temperature resistance and overall strength. Like PET, HDPE is easy to recycle. Recycled HDPE is often used to create plastic lumber, helping to keep more of this material out of landfills after its use as packaging.
• Low-Density Polyethylene (LDPE): This flexible plastic is typically used for plastic bags and films, which, unfortunately, are often one-time-use items. However, LDPE can be recycled into products like trash bags and plastic lumber. By using recycled LDPE for these applications, your company can make significant strides in protecting the environment.
• Post-Consumer Resin (PCR): PCR plastic is made from materials that have already been used, such as recycled food containers or personal care product bottles. Increasing the use of PCR content in your packaging will help reduce your brand’s negative environmental impact and can also potentially align with local sustainability ordinances for environmental protection.

Step 4: Find and Vet Reliable Suppliers

Once you’ve determined which types of plastics will support your sustainability goals, the next step is to find and evaluate potential packaging suppliers. Consider the following factors when choosing a plastics supplier: 

• Clear information regarding their sustainability and recycling process.
• A reliable supply of the specific plastics you need.
• Details about the supplier’s waste management practices.
• Pricing that aligns with your packaging budget.
• The ability to provide sample products for testing purposes.

Step 5: Conduct Feasibility Studies and Pilot Programs

Sustainability goals are necessary, but the fact is that you still need plastic packaging that adequately protects your products and integrates well with your manufacturing process. Before making a complete switch, conduct feasibility studies and pilot programs to test the new packaging. If you have selected the right product and supplier, you should see little difference in performance between the recycled plastic and your previous virgin plastic. These tests will help you avoid the costly mistake of purchasing bulk plastics that may not suit your products.

Step 6: Gradually Implement Packaging Changes

Once you have decided on a new packaging option, implement the change gradually. Continue using your existing plastic packaging, but switch to the new one as you run out. If the change requires adjustments to your packaging and manufacturing processes, make these changes incrementally. For example, if you operate multiple packaging facilities, start by changing one facility before moving on to the next. Similarly, if you have multiple products, switch one product at a time. This gradual approach minimizes disruptions to your packaging operations during the transition.

Step 7: Establish Quality Control Protocols

Whenever you change your packaging, it is crucial to ensure that the modifications do not negatively impact your product or frustrate your customers. To maintain quality control, follow these steps:

• Create a quality control checklist and clearly define quality parameters for your packaging.
• Conduct routine inspections to confirm that the product meets your packaging standards.
• Perform thorough audits and tests to verify that your quality control protocols are effective.
• Train employees to achieve your quality objectives.
• Carry out off-site tests to ensure the packaging performs well in real-world conditions.

Step 8: Track and Report Sustainability Progress

One of the reasons for switching to sustainable packaging is to enhance your brand image. However, if stakeholders are unaware that you are using recycled plastics in your packaging, you may not achieve this goal. Establish a system to track your sustainability progress and report this information to key stakeholders. As you reach important milestones, share these updates with your investors and customers. This approach encourages accountability and transparency, which will further support your growth and enhance your reputation as a sustainable, eco-friendly company.

Ready to Make the Switch to Recycled Materials? We’re Here to Help

Our diverse range of recycled plastic packaging solutions can help you meet your sustainability goals while maintaining product integrity.

 

At Paramount Global, our team of experts is here to guide you through every step of your sustainability journey. Contact us today to connect with a specialist and start planning for a more sustainable future.

Still exploring your options? Check out our Guide to Sustainable Packaging to learn more.