Will Recyclable Flexo Packaging Become Possible?

According to the Flexible Packaging Association (FPA), flexible packaging is the second-largest packaging sector in the United States, accounting for 18% of the $145 billion US packaging market. Lightweight flexible packaging—which includes films and laminates—allows for the transportation of higher product volumes while significantly reducing the raw materials required for production. For brands, this represents a revolutionary shift toward saving on energy and material costs.

From an environmental perspective, flexo packaging is a highly logical choice within the production and consumption cycle. Compared to traditional rigid plastic bottles, flexible packaging has a notably lower environmental footprint. It requires fewer materials to produce, generates less CO2 during transportation, and occupies significantly less space in landfills.

The Efficiency and Sustainability Advantage

The efficiency of flexible packaging is staggering. According to FPA data, flexible stand-up pouches offer a packaging-to-product ratio that is 35 times more efficient than metal-cap glass bottles and 21 times more efficient than aluminum cans. This efficiency allows brands to transport more products using far less packaging material. Furthermore, statistics show that the production of flexo packaging consumes 50% less energy than rigid bottles.

While sustainable packaging is a major focus in the industry, full environmental responsibility is still a work in progress. For many consumers, recycled plastic is seen as the ultimate solution. In fact, producing items from recycled plastic uses 80% less energy than manufacturing new plastic containers. But does this apply seamlessly to flexible packaging?

The Current State of Flexo Packaging Recycling

Currently, there is no formal, widespread closed-loop system for processing flexo packaging recycling, particularly for complex multilayer high-barrier materials and aluminum foil laminates fused with polyethylene (PE) layers.

• Single-layer vs. Multilayer: Single-layer packaging is relatively easier to recycle because it lacks the complex central layers of aluminum foil or other barriers.

• The Separation Challenge: Recycling multilayer flexible PE packaging involves separating each distinct layer—a process that requires far more steps than traditional plastic recycling. Each layer must be analyzed, identified, and processed individually to create a usable recycled resin.

• The Contamination Hurdle: Since a vast amount of flexo packaging is used for food products, food residue contamination poses a significant obstacle. Contamination often runs through current recycling streams, meaning the actual proportion of reusable packaging recovered is quite small. Non-recyclable polymers are often sent to anaerobic chambers for incineration, where they provide monitored emissions energy for production plants.

Industry Initiatives and the Path Forward

Despite these challenges, forward-thinking organizations are driving change. The Flexible Packaging Association (FPA) has adopted a series of robust initiatives and is collaborating closely with manufacturers to develop environmentally safe packaging solutions. Additionally, groups like the Sustainable Plastics Alliance, the Association of Plastic Recyclers (APR), and the Flexible Film Recycling Group (FFRG) are working tirelessly to promote public education and advance the technology behind plastic film recycling.