Material choice

The materials used play a key role in determining the sortability and recyclability of packaging.

Mono-material polyolefin-based packaging is currently preferable to mixed materials, as these are easier to recycle and contribute to improved quality of recycled materials. The guidelines recommend the use of mono-PE and mono-PP structures where possible.

The guidelines also cover the use of paper and aluminium foil in flexible packaging structures.

Barrier layers and coatings

Barrier materials and coatings are an important element of many flexible packaging structures, providing functionality and reducing overall use of materials and resources. The guidelines provide limits for these elements to ensure the choice of barrier material and the amount used does not affect recyclability.

Size, shape and construction

The size, shape and construction of the pack determines how it behaves in a sorting facility. For example, packaging that is too small is likely to fall through holes in screening equipment and end up being sent for energy recovery or landfill. While packs should not be made bigger just to facilitate sortability, the guidelines offer advice on shape and construction to aid the sorting process.

Adhesives

Adhesives play an important role in combining different materials. The total amount of adhesive used should be below specific thresholds to prevent it negatively impacting the recyclate quality.

Inks and lacquers

Printing of flexible packaging provides important product information to consumers, as well as barrier properties. Coverage levels of printing and colours of inks and lacquers can impact the recyclability and the quality of recycled materials.

Additional features

The guidelines advise that materials used for packaging features such as zippers, spouts, closures and valves should be the same as the primary pack material.

Other elements

The guidelines cover other elements such as density, pigments, labels, additives and fillers providing advice on how these can impact the sortability and recyclability.

The guidelines also highlight specific issues, materials and technologies where further research is required to understand the impact of their use on achieving a circular economy for flexible packaging – helping the value chain build these factors into the decision-making and packaging design process wherever possible.