Plastics recycling charity RECOUP has called for more consideration for the effect on overall recyclability when it comes to material switching. It says the trend, made under the promise of plastic reduction strategy, can lull consumers into a false sense of sustainability. Packaging should be assessed as a part of the overall supply chain rather than in isolation.

RECOUP has produced a set of case studies intended to demonstrate the issues and introduce improvements to maximise recovery while minimising environmental impact. The charity stresses the importance of avoiding ‘greenwashing’ when making claims.

Kate Bedford, Packaging Project Manager at RECOUP, explained: “There is a need to make brand owners and packaging designers aware of the factors which need to be considered when looking at changing material. Case Studies communicate what is required.”

Paul East, Head of Packaging, Recycling and Design at RECOUP, says: “A growing number of companies are following the trend to change material types to claim improved sustainability and recyclability, however there are instances when product claims are in danger of lulling consumers into believing such switches are an improvement, when in some instances this is not the case.”

The Recyclability By Design case studies illustrate to consumers and designers how Design for Recyclability principles can be applied to ensure packaging is easily recyclable and displays accurate messaging.

One of the case studies looks at a recent material switch made by M&S for its cherry tomato packaging. The original packaging featured a card tray and film flow wrap, while the new packaging is a ‘luxury’ cardboard box with a plastic film window. The new packaging is multi-material and the plastic window is not removable, making the recycling process more complex. The original packaging was easier to separate into the correct recycling streams and also lighter to pack and transport.

Another case study looks at Garnier’s new ‘more eco-designed packaging’ for shampoo and conditioner products. It states the packaging is ‘75 per cent less plastic with tube made of cardboard [sic]’. This is another example of multi-material packaging, with a High Density Polyethylene (HDPE) lid that cannot be separated from the tube. The inside of the tube is also laminated with plastic and the two layers are held together with adhesives. The packaging also includes no instructions for disposal. The product cannot be mechanically recycled as it contains multi-composite materials.

The report also identifies that many traditional HDPE milk cartons are being switched for Liquid Fibre board packaging, which is already common for soup and juice cartons. Although this has the appearance of cardboard, it is actually a multi-composite material containing a percentage of paper or board, plastic, and sometimes aluminium.

This material is not easily identifiable by the consumer and isn’t commonly accepted by Material Recycling Facilities (MRFs). It is not collected kerbside by most local authorities and there is only one site in the UK with the technology to handle this kind of packaging. Traditional HDPE milk cartons are easily recognisable and have proven circularity.

RECOUP concludes their report by saying that although the manufacturing of packaging and its impact on the environment should remain in the spotlight, it is important to be realistic with new packaging designs to ensure the end life is not overlooked and the packaging can be handled avoiding obstacles to recovery, improving yields and producing less waste. 

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