The short of it: You probably don’t want to use plastic in your packaging. But sometimes you have limited options, so what should you do if you need to use plastic for packaging?
Really, no one will bat an eye if you’re using aluminum, glass, or paper—if it’s from a sustainably managed forest or non-tree pulp. These three materials have high recycling rates and are generally considered “sustainable.” Aluminum and glass are also infinitely recyclable and can be reused.
In fact, Brazil recently claimed a 100% recycling rate for aluminum cans. Wood and cork are also recyclable and compostable, depending on coatings or treatments, and most metals are recyclable. All this to say, there are usually options.
But sometimes, cost or certain performance features make plastic the best momentary option—unfortunately. After all, plastic is cheap cheap cheap (supposedly). Some start-ups need this kind of option to get their product off the ground.
And without reuse systems widely in place, and plastic film barriers needed for many products, disposability and plastic sometimes just win out. But single use plastic has been the main target of so much recent packaging legislation. Consumers also, at the very least, say they want more sustainable packaging.
What about plastic recycling?
There are many reasons for all this legislation and negative attitudes towards plastic. It’s hard to dispose of—recycling, incinerating, landfilling, or polluting the environment are the only four options. And it’s made from fossil fuels, something that climate scientists around the world are urging that we decrease in use. (The US recycling rate for plastic currently hovers around 5%.)
But even if collecting and recycling rates for plastic increased, it’s not enough to cure the problem. The recycling process releases large volumes of microplastics and recycled plastic has been shown to leach more toxic chemicals than its virgin cousin.
The impact of recycling has also been overblown in the minds of consumers and businesses. While recycling is the least desired option from the well-worn phrase reduce, reuse, recycle, it is often the first choice in industry.
With that said, what should you do if you need to use plastic packaging?
Ask Questions
There are a number of questions to ask when looking at using plastic packaging. What properties does it have that requires its use? Is cost the driving factor?
Looking at the first question, there are a number of properties that people look for when using plastic.
- Transparency
- Protection
- Strength and durability
- Flexibility
- Insulation
- Weight
- Airtight level
- Moisture resistance
- Tamper-proof level
- Customization
For each property you require, consider if there’s another material that could do the job or an alternate way of designing your packaging.
As an example, if you need a transparent window for customers to see your product, could paper packaging and a picture of the product on the front work just as well? This obviously depends on the product.
If you need protection or insulation, would molded pulp work just as well?
Regarding the second question of cost being the driving factor, this Zenpack blog looks at the cost of more sustainable materials. And the team has found, on multiple occasions, that plastic free packaging can actually be less expensive than plastic packaging. So if cost is your number one issue, plastic may not actually be the best solution.
Communicate Reality
If you’re going to use plastic packaging, communicate its use realistically. This will help you avoid greenwashing.
As mentioned above, recycled plastic leaches more toxic chemicals than virgin plastic. Using recycled plastic furthers the idea that virgin plastic can have a second life and encourages the continued use of it. Quite honestly, it’s a tricky circle. Because if you have to use plastic, you should recycle it so we can get as much use out of the material as possible. But recycling leads to other issues. As far as packaging is concerned, plastic could be replaced with other materials.
But no matter, the point here is to communicate reality. This means avoiding saying things like “Now with 20% less plastic!” or “We use sustainable recycled plastic.” Both of those statements are false, and are not grounded in reality. Own the use, but don’t try to sugarcoat it.
Understand That It’s a Stepping Stone
If you need to use plastic for a short time until another material is financially available to you, then that happens, especially for start-ups. Spending all your funds on packaging while neglecting other areas of your business is not a recipe for long term growth.
In this situation, while it isn’t ideal to use plastic, understand that it’s a stepping stone until you establish yourself more. At that time, you can source more sustainable, bio-based materials that your brand can pair with your product for years.
Work to Reduce
There are two types of reduction going on here: overall packaging and waste.
If you’re going to use plastic packaging, then one thing you can do to reduce its impact is to design the packaging as efficiently and minimally as possible. If the volume of each individual piece of packaging can be lowered, then you can reduce its impact on the environment and human health.
Additionally, reducing your packaging waste is another important step you can take. This involves both pre-consumer waste, such as what ends up on your production room floor, and post-consumer waste, by helping to increase collection rates of your packaging. While turning off the tap is the best way to reduce plastic waste, a robust collection system is necessary until then.
Use High Value Resin Codes
If you still need to use plastic after exhausting all other options, then using fossil fuel plastics with resin code 1 or 2—those with the highest rate of recycling—would be the preferred traditional plastic in order to increase the likelihood of recycling. These types of plastic, PET and HDPE, are considered the highest value plastics. Using them will increase the likelihood that your packaging will eventually become a lawn chair.
Look Around
There’s always going to be someone who tells you what you want to hear, and if you absolutely want to use plastic, or just don’t care, then you can find someone for that. But if you want to work with a design agency that will consider your product and its journey, and determine the best material for you, then Zenpack is a pretty good place to start. Reach out and let’s see about your packaging needs.
