Designing Plastic Packaging for Sustainability

In nearly every community throughout North America, garbage bins with a recycling symbol full of plastic bottles line the street on waste pickup day. An increasing focus on recycling and limiting plastic consumption has happened in recent years, and for good reason. 

For manufacturers, finding sustainable packaging is essential to meeting the needs of the modern customer. Here is a closer look at the impact of sustainable plastic packaging and the practical steps companies can take to bring better packaging to market for their own customers.

Why Sustainable Plastic Packaging Matters

Sustainable plastic packaging is crucial for today’s businesses for three main reasons. 

• First, choosing eco-friendly packaging helps reduce plastic pollution, minimizing its long-term environmental impact and preserving resources for future generations. 
• Second, consumer demand for sustainable solutions is growing, and companies that prioritize environmentally responsible packaging demonstrate their commitment to meeting customer expectations.
• Third, compliance with evolving environmental regualtions. As more Extended Producer Responsibility (EPR) laws get set, producers are becoming increasingly responsible for the environmental impact of their packaging products.  

Environmental Impact of Traditional Plastic Packaging

Traditional plastic bottles and other plastic packaging have a negative impact on the environment. According to the EPA, 90% of greenhouse gas emissions come from the production and use of plastics. The United Nations warns that it can take up to 500 years for plastic packaging to decompose completely. That means every product packaged in a plastic package leaves behind waste for hundreds of years. Focusing on sustainable plastic packaging can help limit this impact.

Economic and Brand Benefits of Sustainable Packaging

The general public is aware of the dangers and longevity of plastic waste. They want to work with brands that take this problem seriously. In fact, one recent survey showed that 80% of those surveyed were willing to pay more for environmentally friendly products. 

Brands that invest in sustainable practices, including sustainable plastic practices, find themselves more appealing to many consumers. In turn, they may end up with more customers as consumers tend to seek out and support brands with an eco-friendly mission.

5 Practical Steps to Transition to Sustainable Plastic Packaging

So how can a company shift their production to embrace more sustainable plastic packaging, without adding significant cost to their production process? Here are five practical steps that can work well.

1. Conduct a Packaging Audit

The first step in making the switch to more eco-friendly packaging is taking an audit of your current practices. 

Where are you using plastics, and where is waste occurring? Where can you implement recycled materials or flexible packaging options to embrace a more eco-friendly model? Are you using virgin plastic resin to manufacture your bottle? Can you switch to a bottle made with post-consumer recycled resin (PCR)? 

Figuring out where you can make changes will help you know where to spend your effort in looking for a more environmentally friendly option.

2. Collaborate with Sustainable Packaging Suppliers

Once you find where you can make improvements, find packaging industry partners to collaborate with. Explore eco-friendly packaging solutions that work for your particular industry. 

The suppliers will have ideas on how to add environmentally friendly materials to your packaging without sacrificing the safety of your products. They can also suggest the best design to limit the amount of plastic in your packaging, without hurting its quality. Working with the right supplier can help you find the products that align with all of your business goals.

3. Select Sustainable Plastic Packaging Materials

A key to making the switch to environmentally friendly materials is moving away from single use plastics and opting for more sustainable options. This does not necessarily mean you should never use plastic again, but you need to look for products that reduce plastic packaging waste rather than adding to it. There are several ways to do this, including:

• Choosing recyclable packaging – Using recyclable plastics makes it possible for your customers to recycle the product packaging once the product has been finished. Ideally, you want your customers to be able to easily recycle the product to eliminate waste and ensure that it stays out of landfills or oceans. When plastic is recycled properly, it gets melted down and remade into something new.  
• Choosing bioplastic packaging – Bioplastic packaging is made from plant-based biomass, such as bio-based sugarcane polyethylene. Bioplastics are a renewable-sourced material with the same structural look and feel of standard PET tubes but require far less fossil fuels to produce than virgin plastic manufacturing. Many bioplastic options are just as sturdy as plastic but without the lasting environmental impact.
• Choosing reusable packaging – Some types of packaging, such as glass, can be sanitized and reused infinitely. This makes your packaging part of the circular economy and limits waste.  

4. Choose the Right Packaging Shape and Size

Custom-sized packaging can help cut down on plastic waste as well. Rather than packaging your item in an oversized container, choose one that is the exact size you need. In addition, with the right-sized packaging, you can transport more containers in each truckload, cutting down on emissions and fuel use.

5. Use Eco-Friendly Inks and Labels

Finally, when considering the sustainability of your packaging, don’t just look at the plastic itself. You need to look at the entire package. For instance, inks can carry a heavy toxin load, and labels with adhesives can be less sustainable than you might think. Choose soy or water-based inks, which create fewer toxic chemicals than other types of ink, and look for biodegradable labels and adhesive products.

Regulatory Considerations for Sustainable Plastic Packaging

As we continue to make progress in more sustainable manufacturing practices, rules and regulations surrounding sustainable plastic packaging are coming to the forefront. Some focus on helping brands choose sustainable packaging practices, while others aim to prevent the use of more toxic chemicals. Some that are currently in place include:

• European Packaging Directive – In place across Europe, the EPD focuses on right-sized packaging. By 2030, packaging can have no more than 50% voids or empty space inside to comply.
• State-Based Extended Producer Responsibility Laws – These EPR laws, implemented in many states throughout the United States, charge producers higher fees if they use plastic products that are not likely to be recycled, creating incentives to make changes.
• Break Free From Plastic Pollution Act of 2023 – This recently introduced legislation, if put into law, will hold producers responsible for the environmental impact of their plastic use, similar to the state-based regulations, but on a national level.

These are just a few examples of legislation in the works to help reduce the amount of plastic used in modern manufacturing. Other areas, including Asia, have similar regulations. In today’s global economy, it makes sense to pay attention to these rules and adjust accordingly.

Taking the Next Steps Towards Sustainable Plastic Packaging

Consumers want sustainable packaging. In both the United States and Europe, regulations are in play that will further incentivize these changes. Now is the time to start taking steps towards more sustainable plastic packaging and finding the right partners to make these changes. Paramount Global can be that partner. 

At Paramount Global, we have been helping businesses like yours reach their packaging goals since 1976. Not sure if moving into sustainable packaging is right for you? Contact us today to learn more!