Design Principles

Design is where the circular economy begins. If we don’t get it right at the start, we compromise everything that follows.

Flexible packaging plays a vital role in protecting goods, reducing food waste and using fewer resources. It includes a range of formats and materials, with each structure and combination of elements designed to meet specific packaging functionalities. For example, some products demand gas and moisture barrier, others stiffness.

But even with these specific functionality requirements, there are sustainable design principles that can be followed to support designing flexible packaging for a circular economy.

For example, D4ACE expresses a preference for mono-PE and mono-PP over polyolefin mixes and multilayer-multimaterial structures. These deliver the best sortability, recyclability and yield in mechanical recycling plus recyclate quality. This expands the range and value of possible end market applications for recycled content and supports the business case of the circular economy.


Diagram showing Preference for plastic recycling streams from post-consumer polyolefin-based flexible packaging

Applying robust and detailed design principles is critical to:

  • Meeting EU Packaging and Packaging Waste Regulation (PPWR) requirements for recyclability and recycled content by 2030 and 2035 recycling rates
  • Improving collection, sorting and recycling yields Producing higher-quality recyclate for use in new and demanding end markets
  • Lowering costs and risks across the value chain

Design principles in practice

  1. Material choice – Favour mono-PE or mono-PP structures wherever possible to maximise recyclability and recyclate quality.
  2. Barrier layers and coatings – Use within defined thresholds to balance functionality with recyclability.
  3. Size, shape and construction – Ensure designs can be captured and sorted effectively in sorting and recycling facilities.
  4. Inks, adhesives and varnishes – Follow updated thresholds and guidance to prevent contamination and maintain quality.
  5. Additional features – Align closures, spouts and zips with the main material stream to avoid disruption.

Future-ready, open by design

D4ACE is not about perfection or owning the answers – it’s about making meaningful progress together and staying ready for what comes next.

The guidelines will continue to be updated regularly as data, technologies and legislation evolve, keeping you ahead of compliance and helping accelerate the circular economy for flexible packaging.

The 2025 D4ACE guidance is closely aligned with the direction of EU regulation, particularly the Packaging and Packaging Waste Regulation (PPWR) and forthcoming Design for Recycling (DfR) criteria CEN standards and specifications.