Sustainable Packaging Systems

Circularity design guide for plastic packaging Introduction Contents

Packaging protects and preserves food and consumer goods products and gives a platform to inform the consumer about the product. Specifically, plastic packaging provides product durability, flexibility in design, hygiene and safety properties and can extend . However, following rising public concern about the rise in plastic waste, inconsistencies with collection and facilities in the UK, and the increase of marine pollution, consumers are asking retailers and brands to minimise use and dependency on plastic.

Whether you’re a senior technologist on a mission, an operations manager responding to client demands or a buyer with targets, this IGD guide will:

• Talk you through the key principles • Give you a 5 step design approach • Provide supporting insights and action points

2 SUSTAINABLE SUSTAINABLE 3 PACKAGING PACKAGING SYSTEMS SYSTEMS Understanding circularity Moving to a circular economy and the waste hierarchy Resources

The plastics life cycle currently follows a predominantly The Ellen MacArthur Foundation’s Circular Economy Butterfly linear model that follows the path of raw material extraction, Diagram gives a useful structure to adopt circularity within Minimise Manufacture manufacture, product design and moulding, product use and sustainable design focused on: then disposal. As part of industry initiatives and commitments Remove Reprocessed/ recycled material such as the UK Plastics Pact, the aim is to ensure that where • Remove – eliminating unnecessary packaging Reduce Design plastic is used a circular approach is adopted. • Reduce – using less packaging such as light-weighting Recycle content • – using the same material over and over e.g. multi- Circularity aims to keep the resources in use for as long as use , refillable , reusable coffee cups possible–extracting its maximum value through maximum use/ Optimise 3 - Recycle reuse. It then encourages the effective collection and sorting • Recycle and use recycled material– segregating, collecting 1 - Minimise/ and sorting used packaging. Increase the amount of share/prolong of used material, recycling and remoulding (the adoption of Reuse Use recycled plastic content in new products over the use of virgin recycled content used (avoiding virgin materials) Recycle 2 - Reuse/ plastic). refill

Prepare

Leakage End of use/ recovery waste

4 SUSTAINABLE SUSTAINABLE 5 PACKAGING PACKAGING SYSTEMS SYSTEMS Industry ambitions Five step plan Sustainable Design Principles The food and consumer goods industry has responded by setting commitments around plastic reduction and dependency on plastic, increasing recyclability and recoverability of packaging, increasing reuse When designing the most appropriate packaging solution to and adopting circular economy principles. protect the product, it’s important to ensure that it’s designed

in a way that reduces its environmental–both waste and The UK Plastics Pact is an initiative launched by WRAP and the Ellen carbon–impact. Decisions should be made based on its whole MacArthur Foundation that tackles the issue of plastic waste in the UK. 70% life cycle (source, type, usability and recyclability). This is known as the ‘cradle to cradle’ approach. The Pact brings together stakeholders involved in making, using, Nearly 70% collecting, sorting, reusing and recycling plastics in order to transform of UK plastic The Guide enables you to ask the following key questions at the system; agreeing collectively to: waste is from each step: 1. Eliminate problematic or unnecessary single-use packaging through packaging* redesign, innovation or alternative delivery model 2. 100% of plastics packaging to be reusable, recyclable or compostable 3. 70% of plastics packaging effectively recycled/composted 4. 30% average recycled content across plastic packaging

An associated roadmap has been developed to support members to achieve these targets by outlining key activities that could be taken by all parts of the supply chain.

At each of these phases, it’s important to question whether there are any potential unintended consequences. 6 SUSTAINABLE *WRAP SUSTAINABLE 7 PACKAGING PACKAGING SYSTEMS SYSTEMS Developing a packaging inventory will help Action notes to assess current plastics usage. Complete an inventory of your packaging products, Identify where you can have scope and opportunity to change, identifying: prioritise based on risk and produce a strategy or action plan. • Where plastics are used and in what format The packaging inventory should include a list of your plastic • Their recyclability and recovery performance (refer packaging products (start with highest volume where you have to Step 5) significant quantities). Then list polymer type(s), add major • Whether they include any ‘problem plastics’ for elimination or review constituents (e.g. plastic on card, plastic on plastic, plastic on metal foil etc.), followed by a recyclability review. Prioritise based on risk, client requirements and develop a strategy and/or action plan. Assess your Review your inventory against the 8 ‘problem’ plastics that will be eliminated as part of the UK Plastics Pact commitments, Remember to include questioning for unintended including single use disposal plastic cutlery, cotton buds with consequences within your strategy such as reducing plastic stems, plastic stirrers and plastic straws. shelf life, increasing food waste or , or plastic use creating recycling challenges. Note that there are a further 19 more ‘problem’ plastics being actively investigated to test viability of their continued use. These include single use drinks , non-detectable black plastic packaging that’s not readily picked up in the recycling 8 problem plastics process, and a range of flexible plastics and films in everyday

use. A full list is available from WRAP. Focus on these for action 1. Disposable plastic cutlery areas in the next steps. 2. All polystyrene packaging 3. Cotton buds with plastic stems 4. Plastic stirrers 5. Plastic straws 6. Oxo-degradables that break down to create microplastics 7. PVC packaging 8. Disposable plastic plates and bowls 8 SUSTAINABLE SUSTAINABLE 9 PACKAGING PACKAGING SYSTEMS SYSTEMS Identify opportunities to remove or reduce Action notes the amount of unnecessary plastic material. Check for unintended consequences, such as removing Using your inventory, review whether any of the following packaging not increasing food waste and the lighter sustainable design considerations work without affecting the the packaging, the more easily it can be littered (blown suitability of the packaging to protect the product: away). Be careful not to create new problems for our environment by switching to other materials without Remove packaging: Can the packaging be removed? E.g. on proper research, testing and evaluation of potential produce items or removing an outer layer or multipack film– consequences. For example: and focus on price points. • Switching to aluminium has higher carbon Remove and Light-weighting: Can the plastic be made lighter? This will lead implications to less material and support commercial saving programmes. • Compostables must have an appropriate collection and reprocessing system at point of disposal Smaller pack sizes: Can the packaging be made smaller whilst • Biodegradables have varying qualities and reduce plastic still serving its purpose? Focus on smarter branding approaches timeframes and improved store display and stacking.

Note that oxo-degradables, which break down to create Identify alternatives to plastic: Would another packaging microplastics, will be banned by 2021 and should not be in design material be more sustainable and work just as well? Ensure used. whole life cycle–cradle to cradle approach is considered, including environmental risks and carbon emissions.

Increase concentration: Review whether you can make your products more concentrated, or even solid. This reduces the amount of packaging needed and may make the technical requirements of the packaging less demanding.

10 SUSTAINABLE SUSTAINABLE 11 PACKAGING PACKAGING SYSTEMS SYSTEMS One of the main concerns about plastic Action notes packaging is that it’s only used once and thrown away. Identify where reuse solutions could be developed and adopted. Consult with trade bodies, retail, grocery Reuse models, enabled by technologies and shifting user and food-to-go teams to discuss current initiatives and preferences, can unlock significant benefits and has a higher trials. See if you can be part of these if relevant. circularity loop than recycling. Such models can help to deliver superior user experience, customise products to individual Check whether you can produce a refill version. Consult needs, gather user insights, build brand loyalty and optimise with trade bodies, etc, for initiatives in this area to align operations. with market-wide standards.

Reusability There is no one size fits all option for new reusable/refillable packaging that will be applicable to every company, product or geography. Identify whether your product(s) has the potential The Ellen MacArthur Reuse Guide to support a returnable, refillable or reusable solution. This highlights 4 reuse models: could include removing single use bags, in store and online refillable homecare and dried products, food-to-go returnable Refill at home Return from home 1 2 and reusable containers, ‘naked’ produce, and reusable drink users refill their packaging is picked up cups. Several study examples are highlighted in the Ellen reusable at from home by a pick- home (e.g. with refills up service (e.g. by a MacArthur Reuse Guide. delivered through logistics company) subscription service) The following principles should be considered when designing Refill on the go Return on the go a scheme and enabling the shift to mainstreaming reusable/ 3 4 users refill their users return the refillable solutions: durability of the reusable/refillable reusable container packaging at a store packaging, affordability, non-toxic, convenient (for various away from home or drop-off point (e.g. (e.g. at an in-store in a deposit return lifestyles and shopping styles), simple and supports a transition dispensing system) machine or imailbox) to increased circularity.

12 SUSTAINABLE SUSTAINABLE 13 PACKAGING PACKAGING SYSTEMS SYSTEMS Plastic packaging should include recycled Action notes plastic where it can legally be achieved. Talk to your plastics manufacturer to discuss recycled This would make the plastics economy as effective and content allocations appropriate to your products– commercially viable as possible and would ultimately minimise taking into account food contact considerations. It may use of virgin plastic (and its linear life cycle approach). increase packaging costs and a business case may be required. It may not suitable for all types of plastic or This increases the demand for recycling plastic by increasing its products. value and helping to close the loop–making it circular. Note that some food contact conditions do not allow for recycled plastic Using recycled to be used. As a guide, most packaging should have at least 30% post- consumer recycled (PCR) content by 2025. The UK Plastics Pact Roadmap details the ambitions for levels of recycled content plastics per plastic by 2025. For food contact packaging, there are only legally valid processes for PET and for HDPE milk bottles (not available for PP or for films).

Several non-food businesses are now including an element of ocean plastic. This is where waste plastics found in the oceans and seas around the world have been collected and remanufactured into plastic pellets for a new use.

14 SUSTAINABLE SUSTAINABLE 15 PACKAGING PACKAGING SYSTEMS SYSTEMS In the UK, we currently recycle around 50% Key points to consider of plastic bottles and just 12-15% of mixed plastics*. when trying to ensure that your plastic Most plastic polymers can theoretically be recycled, however packaging can be in reality some are more likely to be recycled than others for reasons including product format, infrastructure (such as widely recycled sorting technologies) and economics.

It’s important to think about where the end product is likely to be consumed and packaging disposed of, and whether Maxismising a recycling solution is in place to process your packaging material.

Plastics that can be recycled in the UK are termed as widely recovery and recycled as per The On-Pack Recycling (OPRL) guidelines and products can be labelled as such for consumer knowledge and action. Widely recycled means that UK waste recyclability management companies and infrastructure have the capacity to collect, sort and batch the right type of plastics together to be sent for recycling. Widely recycled should be a general ambition for your packaging solution.

*WRAP

16 SUSTAINABLE SUSTAINABLE 17 PACKAGING PACKAGING SYSTEMS SYSTEMS What type(s) of Main plastic resin types and Action notes plastic polymers is their applications in packaging Commit to adopting a widely recycled packaging your packaging? solution if it’s right for your product. You should:

• Avoid coloured opaque PET bottles (use clear and As part of your packaging inventory, identify which plastic uncoloured), PVC sleeves and components, silicone 1 PET 5 PP types are used so you can determine whether it can be widely seals or valves - alternatives that are compatible recycled in the UK. Note that there may be more than one type with the recycling process are underway (WRAP) per product, e.g. , linings and sleeves). • Eliminate polystyrene • Manage any problem plastics used 2 HDPE 6 PS The symbol on plastics packaging identifies the type of plastic

it’s made of, but it does not give a guarantee that it’s recycled or Note that widely recycled does not necessarily mean recyclable. Uncoloured, unpigmented PET has the highest that they are recycled. It’s worth performing an value, the highest recovery rate and the widest variety of end additional test to see whether the products are actually 3 PVC 6 EPS markets (WRAP and RECOUP design guide).Flexible plastics recycled at your likely disposal points. (films, pouches and bags) are designed to be incredibly efficient, cost effective and lightweight. This means they’re also hard to recycle. 4 LDPE 7 OTHERS As part of the UK Plastics Pact and upcoming legislative requirements, all polystyrene, oxo-degradables and PVC should be eliminated. Source: WRAP

18 SUSTAINABLE SUSTAINABLE 19 PACKAGING PACKAGING SYSTEMS SYSTEMS Does your packaging Does your packaging also consist of one or more include non-plastic materials?

different types of plastic? For example, aluminium/metal closures on bottles, aluminum foil in wrappers, card-based sleeves or silicone valves used with PET bottles. Multiple polymers are difficult to recycle. For example, Action notes resealable tabs and clasps, sleeves are often PVC, and multi- Having a complex mix of packaging materials makes the layer laminates and PE sealing layers. Action notes sorting process within the recycling chain extremely difficult, Try to minimise complexity of materials. Replace with plastic alternatives that can be widely recycled. Avoid often leading to contaminated batches and low value For PET/PE and other multi-layer laminates, used in the sleeves that cover more than 40% of the packaging Adopt a one plastics polymer solution where feasible. reprocessed material. Sleeves with more than 60% surface area processed meat sector for example, the recycling sorting (60% for tubs pots and trays)–and ensure that they Review against shelf life extension value of product. coverage, for example, can lead to error in its identification of process has limited capacity to effectively differentiate and can be easily removed by the user (perforation and Focus on recovery and review where it’s likely to be the material in the sorting process. separate between the types of plastic–limiting the recycling labelling). Do not use trigger sprays with metal collected, sorted and processed. capacity and risking higher levels of contamination and lead to components. Focus on recovery and review where it’s low value recyclate. likely to be collected, sorted and processed.

There is a move among many brands and retailers to have only one type of plastic polymer per packaging product, category or entire product list that can be widely recycled within the UK. This is particularly important for plastic trays which are the heavier weight plastic component in a pack.

20 SUSTAINABLE SUSTAINABLE 21 PACKAGING PACKAGING SYSTEMS SYSTEMS Is your packaging Are you using biodegradable black plastic? or compostable plastics?

Black plastic cannot be widely recycled within the UK. The Bio-based plastics fall into two broad categories: biodegradable/ infrastructure is not widely adopted in that plastic containing compostable and non–biodegradable (i.e. which have the same Biodegradable can be a misleading term as it simply means carbon black pigment cannot be detected in the sorting phase properties as conventional plastics e.g. bio-PET). These plastics that a plastic will break down naturally, but it doesn’t specify and results in the plastic being classed as waste. Action notes are designed to generally break down rather than be recycled. the conditions in which this will occur or to what extent the

They cannot therefore enter the recycling system–and in fact plastic will break down. This means that biodegradability Avoid black plastic and in future plans, reduce the With support from some businesses, the waste management cause high levels of contamination and reduce the confidence cannot be recommended for all circumstances. industry is actively investing in this recycling infrastructure to amount of coloured PET. Amorphous of the end-market in the durability of materials made from terephthalate (APET) can be clear; high density support its brands. However, retailers will switch from black recyclate. Compostable is less ambiguous as it means that the plastic polyethylene (HDPE), (PP) and crystalline plastic trays by March 2020 to clear and neutral colours, which will break down under the conditions of an industrial or polyethylene terephthalate (CPET) can all be colours can be widely recycled through home collections. Further research and life cycle analysis are needed into the home composter. For compostable packaging to be handled with no carbon black pigment. impact of bio-based conventional plastics and compostable sustainably at end-of-use it needs to be collected and taken packaging across the supply chain. It’s likely that the to a composting facility that can reprocesses it. Coloured PP has a better end-market, but future credentials of bio-based plastics will depend on developments may be able toresult in the ability to put the specific circumstances in which they’re produced, used and For more insight, see WRAP’s Considerations for compostable plastic packaging PP back into food contact. then handled at end-of-life.

There are huge industry challenges around these materials. compostable plastics. However, in some circumstances Industrial composters are removing all biodegradable/ compostability would be an advantage, for instance to promote compostable plastics from their facilities as they cannot food waste collections (caddy bags) or to reduce plastic currently differentiate between non-compostable and pollution (tea bags, fruit ).

22 SUSTAINABLE SUSTAINABLE 23 PACKAGING PACKAGING SYSTEMS SYSTEMS Action notes References

If using compostable plastics, ensure that there is a known Baxter Storey, The Future of Foodservice Packaging (2019) https://www. Recoup, Recyclability by Design (2017) http://www.recoup.org/p/321/ foodservicefootprint.com/new-report-launch-the-future-of-foodservice- recyclability-by-design-versions supporting compostable system (e.g. closed loop–offices, stores, packaging-in-association-with-baxterstorey/ events) where they can be collected and sorted separately from Recoup, Core Principles – A summary of Recyclability by Design (2019) http:// BBIA, Plastic Atlas: Facts and figures about the world of synthetic polymers www.recoup.org/p/321/recyclability-by-design-versions other plastic products–or that they provide an advantage. They (2019) https://bbia.org.uk/wp-content/uploads/2019/11/Plastic-Atlas-2019.pdf need to be clearly labelled to ensure that they are disposed of UK Plastics Pact WRAP http://www.wrap.org.uk/content/the-uk-plastics-pa Ellen MacArthur Foundation, Circular Economy Principles – Systems Diagram ct?gclid=Cj0KCQjwrrXtBRCKARIsAMbU6bGTkdGl0gEV4qmQ3eQIGgf- appropriately by the user to minimise contamination. ‘Butterfly’ https://www.ellenmacarthurfoundation.org/assets/images/circular- PJyw55CFxFuuYWYDrbsX4hLd_RThpJcaAvDbEALw_wcB economy/System_diagram_cropped.jpg UK Plastics Pact WRAP, A Roadmap to 2025 - http://www.wrap.org.uk/sites/ For best practice compostable carrier bags, review the Ellen MacArthur Foundation, The New Plastics Economy: Rethinking files/wrap/The-UK-Plastics-Pact-Roadmap-v3.pdf Provision of Compostable Carrier Bags October 2019 guide. the future of plastics & catalysing action (2016). https://www. ellenmacarthurfoundation.org/publications/the-new-plastics-economy- UK Plastics Pact WRAP, Eliminating Problem Plastics (2019) https://www.wrap. rethinking-the-future-of-plastics-catalysing-action org.uk/sites/files/wrap/Eliminating-problem-plastics-v2_0.pdf

Ellen MacArthur Foundation, The New Plastics Economy: Catalysing action UK Plastics Pact WRAP & RECOUP, Rigid Plastic Packaging – Design Tips for (2017) https://www.ellenmacarthurfoundation.org/assets/downloads/New- Recycling (2018) https://wrap.org.uk/sites/files/wrap/Design%20tips%20for%20 Plastics-Economy_Catalysing-Action_13-1-17.pdf making%20rigid%20plastic%20packaging%20more%20recyclable.pdf

Ellen MacArthur Foundation, Reuse Rethinking Packaging (2019) https:// UK Plastics Pact WRAP, Considerations for Compostable Plastic Packaging, www.ellenmacarthurfoundation.org/assets/downloads/Reuse.pdf (2020) https://www.wrap.org.uk/sites/files/wrap/Considerations-for- compostable-plastic-packaging.pdf INCPEN & WRAP, UK Survey on citizens attitudes & behaviours relating to food waste, packaging and plastics packaging (2019), https://www.wrap.org.uk/sites/ World Wildlife Fund (WWF), A Plastic Future: Plastics Consumption and files/wrap/Citizen-attitudes-survey-food-waste-and-packaging.pdf Waste Management in the UK (2018) https://www.wwf.org.uk/sites/default/ files/2018-03/WWF_Plastics_Consumption_Report_Final.pdf OPRL – The On-Pack Recycling Label (2019) https://www.oprl.org.uk/

24 SUSTAINABLE SUSTAINABLE 25 PACKAGING PACKAGING SYSTEMS SYSTEMS Further information

Thank you to all the people who commented and gave their technical expertise in completing this guide.

For more information, refer to IGD Sustainable Packaging Systems useful links.

26 SUSTAINABLE PACKAGING SYSTEMS