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Will 100% recyclable flexible packaging become possible?
Flexible packaging has become a significant segment in the U.S. packaging industry, ranking as the second-largest category and contributing 18% to the $145 billion market. This type of packaging, which includes films and laminates, is known for its lightweight nature, allowing for more efficient transportation of goods while reducing the amount of raw materials needed. For brands, this shift toward lighter and more resource-efficient packaging represents a major cost-saving strategy, helping to cut energy and material expenses.
From an environmental perspective, flexible packaging is often considered more sustainable than rigid alternatives like plastic bottles or metal containers. It uses less material during production, generates fewer carbon emissions during transport, and occupies less space in landfills. According to the Flexible Packaging Association (FPA), upright flexible bags are 35 times more efficient than glass bottles with metal lids and 21 times more efficient than aluminum cans. Additionally, flexible packaging requires 50% less energy and 60% less plastic compared to rigid packaging during the manufacturing process.
While sustainability is a key selling point, full environmental responsibility remains a challenge. Recycling is often seen as the solution, but it's not always straightforward—especially for multi-layer flexible packaging that contains aluminum and polyethylene layers. These complex structures are harder to recycle because they require separating each layer before processing. Single-layer films, on the other hand, are easier to handle in traditional recycling systems.
Food contamination is another major issue when it comes to recycling flexible packaging. Many packages used for food items end up in the waste stream, making them unsuitable for reuse. As a result, only a small percentage of flexible packaging is actually recycled. Instead, non-recyclable plastics are often incinerated, which can provide energy but also releases harmful emissions.
To address these challenges, organizations like the Flexible Packaging Association (FPA) and the Sustainable Plastics Alliance are promoting better recycling practices and public awareness. Some companies are exploring innovative solutions such as cradle-to-cradle design, where products are designed to be fully reusable or recyclable without degrading quality. Enval, for example, has developed a method to recover aluminum from polymer laminates and convert plastic into usable fuel through pyrolysis.
Manufacturers are also turning to biodegradable and bio-based materials, which not only reduce environmental impact but also support agricultural growth. By using plant-based components, the industry helps boost demand for crops, further stimulating the agricultural sector.
Currently, pyrolysis is one of the most promising methods for handling multi-layer flexible packaging waste. It converts plastics into liquid and gaseous fuels without producing COâ‚‚, offering a cleaner alternative to incineration. However, more research is needed to improve the efficiency and scalability of this process. With ongoing innovations in sustainable materials and recycling technologies, the future of flexible packaging looks increasingly eco-friendly and economically viable.