Mini-masterclass

The following mini-masterclass serves as a representation of our full-length masterclass on recycling and is displayed in a Q&A format. In it, we introduce you to the critical concepts of packaging recyclability, share insights from our extensive industry experience, and provide practical tools to help you improve your packaging’s environmental impact. Whether you’re new to the subject or looking to deepen your expertise, these three modules are designed to equip you with the knowledge and confidence.

Our qualifications

As a key player in supporting brand owners and packaging companies, CIRCPACK helps you understand, assess, and enhance the recyclability of your packaging. What sets us apart is our material-agnostic approach and our strong belief in the benefits of harmonisation and cross-country alignment. These principles drive everything we do.

As part of the Veolia group, we are uniquely positioned to offer global expertise combined with local knowledge. With Veolia’s extensive network spanning 50 countries and supported by over 210,000 employees, CIRCPACK has unparalleled access to the latest innovations and operational facilities worldwide.

Module 1: Collection, Sorting and Reprocessing

This module offers a concise overview of the key aspects of recycling packaging waste. It explains what makes packaging recyclable, the importance of collection and sorting, and the role of Material Recovery Facilities (MRFs). The module also covers global variations in recycling systems, the technologies and innovations driving the industry, and why recycling practices differ between countries. This knowledge is essential for understanding how to design and manage packaging for optimal recyclability.

1.1 Recyclability

Recyclability refers to the ability of packaging to be efficiently collected, sorted, and reprocessed so that its materials can be reused in new applications. Of these four steps, collection and sorting represent the most important checkpoints for your packaging. True recyclability is influenced by several factors, including the availability of recycling infrastructure, market demand for recycled materials, and the overall business case of the recycling process.

At CIRCPACK, we leverage an extensive database that covers the recyclability of over 50 packaging format combinations across 71 countries. This wealth of information, accessible through our ReCoRe platform, helps us determine how likely your packaging is to be successfully recycled.

1.2 The basics

Collection and sorting are the backbone of the recycling process, together representing about 80% of the effort required to make recycling work effectively. These two steps are crucial in ensuring that recyclable materials are properly managed from the moment they are disposed of, so that they might find their way to a reprocessor.

You might wonder why we don’t use the terms "recycling" or "recycler" in this context. CIRCPACK sees the recycling process as being composed of four steps:

Collection of a material ensures the
sorting of a material, which ensures that it is
reprocessed into a new raw material, which can be
applied [1] to a new product.

The final step in the recycling process is often overlook, as it is the application of reprocessed materials into new products. This step ensures that the recycled materials are effectively reintegrated into the production cycle, reducing the need for virgin resources and contributing to a circular economy. The success of this stage depends on the quality and compatibility of the reprocessed material with its intended use, as well as market demand for products made from recycled content.

Collection is a critical first step in the recycling process because it ensures that recyclable materials are captured and not lost to landfills or incineration.

Proper collection gathers all possible materials, creating the foundation for effective recycling. Without efficient collection systems, valuable recyclable materials may never reach the sorting or reprocessing stages, undermining the entire recycling effort.

Sorting is essential because it separates collected materials into their respective streams, directly impacting the quality and efficiency of the reprocessing stages. This often occurs at a MRF.

Effective sorting ensures that materials are properly categorised, preventing contamination and maximising the potential for high-quality recycling. Even the most recyclable packaging can be rendered useless if not correctly sorted, making this step vital for the success of the recycling process.

The reprocessing [2] infrastructure for packaging waste is composed of specialised facilities tailored to handle different materials. Once properly sorted material gets to this step, it is often likely to be recycled into a new raw material.

For example, specific paper grades are sent to paper mills, beverage cartons go to specialised mills designed to handle composite materials, and various types of plastics are directed to reprocessors equipped to manage specific polymers. Similarly, glass, metals, and wood are sent to dedicated reprocessors that specialise in reclaiming these materials for reuse.

A Material Recovery Facility (MRF) [3] is a specialised plant designed to sort and process household waste into distinct material fractions, such as plastics, metals, paper, and glass.

Once sorted, these materials are directed to reprocessors, each specialising in recycling a particular type of material, ensuring that waste is converted back into valuable resources as efficiently as possible. The effectiveness of a MRF can vary widely depending on the technology used, the design of the facility, and the local recycling infrastructure. For example, collection systems which implement source separation, often in the form of different waste bins, have a significant impact on the efficiency of MRFs.

1.3 Technologies and locality

The effectiveness of recycling systems are deeply influenced by the technologies used in collection and sorting, as well as the local context in which they operate. Advanced technologies play a crucial role in optimising the recycling process, from the initial collection of materials to their precise sorting within facilities. However, the maturity and sophistication of these systems can vary widely across different regions, leading to significant differences in recycling outcomes.

Low-tech solutions, such as incentivising citizens to separate waste or collect bottles and cans with deposits, can catch a significant portion of the so called "low-hanging fruit" in a recycling context.

Understanding the local factors that drive these variations—ranging from technological capabilities to economic and cultural influences—is more important than ever.

Collection systems for packaging waste vary widely, not only between countries but often within the same country. For instance, in the UK alone, there are 39 different bin collection regimes managed by 391 Local Authorities, each with its own set of rules and practices. In the United States, the diversity is even greater, with over 3,000 distinct recycling initiatives spread across 50 states. Similarly, across Europe, bin types, colours, and sorting methods can differ significantly from one country to another. However, the upcoming PPWR aims to harmonise these systems to reduce such disparities in the European Union.

To navigate these complexities, ReCoRe provides detailed insights into the collection systems within each country, allowing you to compare different approaches easily. Our platform’s compare tool makes it simple to analyse these variations, helping you understand how collection systems may impact the recyclability of your packaging. For a closer look, you can explore our freely available Italy report.

Collection and sorting infrastructure varies significantly both within and between countries, shaped by factors like local policies, investment in recycling technologies, and public engagement. While some regions boast advanced systems with cutting-edge technology, others rely on more basic or even informal methods. However, it’s important to note that the level of technology does not always equate to the effectiveness of recycling systems.

For example, Brazil, despite having less advanced technology available than some areas, achieves a recycling rate for aluminium cans comparable to that of leaders in recycling. This is largely due to the extensive network of informal waste collectors who play a crucial role in the recycling process by targeting and sorting valuable waste flows. This shows that different systems can be equally effective, even if they operate differently.

To help you understand these dynamics, our ReCoRe platform provides a colour-coded map detailing the maturity of collection and sorting systems across the globe. This tool allows you to compare and assess the effectiveness of recycling systems in different regions, enabling you to make informed decisions about your packaging strategies based on local conditions via a basis of comparison.

Advancements in technology have significantly enhanced both the collection and sorting of packaging waste, making these processes more efficient and effective.

In terms of collection, the use of differentiated curbside bins remains standard in many regions, allowing households to easily separate their recyclables. Additionally, reverse vending machines have popped up in areas with Deposit Return Schemes, enabling consumers to return beverage containers for a refund. Smart bins equipped with fill-level sensors are another innovation, helping waste management services optimise collection routes and reduce operational costs.

When it comes to sorting, a variety of technologies are employed both outside and inside sorting facilities. Mechanical sorting often begins with a barrel drum, which separate materials based on size. Optical sorting technologies, such as Near-Infrared (NIR) detection, are used to identify and separate different types of plastics and other materials. Eddy current separators are used to sort non-ferrous metals, while magnetic separators handle ferrous metals. Ballistic separators are used to sort between 3d and 2d packaging formats.

The integration of Artificial Intelligence (AI) has further revolutionised sorting in new ways, with robotic arms now capable of accurately identifying and ejecting specific types of packaging based on programmed criteria. This AI-driven technology represents another approach to increasing the precision and speed of sorting, helping to maximise the recovery of recyclable materials.

Recycling systems vary widely across countries due to a complex mix of factors including political decisions, economic conditions, cultural awareness, consumer behaviour, market dynamics, historical context, and the availability of infrastructure and investment. Each of these elements influences how waste is managed, from the way materials are sorted to the technologies used for reprocessing.

As a result, no two countries approach recycling in exactly the same way, leading to significant differences in efficiency and effectiveness.

1.4 Innovation

The waste management industry is experiencing a wave of innovations that span from product design materials to cutting-edge technologies in recycling facilities. Among these, Artificial Intelligence (AI) has become an investment hub, with AI-powered robotic arms now being used to enhance the precision and efficiency of the sorting process by accurately identifying and separating materials.

Another groundbreaking innovation is the so-called HolyGrail 2.0, or digital watermarking initiative, which pioneers the use of digital watermarks in packaging. These watermarks, invisible to the naked eye, can be detected by specialised sorting equipment, allowing for more accurate sorting and recycling of materials.

Module 2: Design and Certification

Below you’ll learn the preliminary requirements for creating packaging that is easily recyclable. We explain the principles of DfR, the importance of obtaining recyclability certification, and offer access to free DfR guidelines. The module also guides you on how to assess your packaging’s recyclability before formal certification and provides detailed information on country-specific recyclability schemes, ensuring your packaging meets local and international standards.

2.1 Design for Recycling (DfR)

Design for Recycling (DfR or D4R) in the packaging world refers to creating packaging solutions that are easily recyclable at the end of their use. This approach involves several key practices, including but not limited to:

Using single materials within packaging instead of mixed, or composites.
Minimising unnecessary packaging layers
Utilising packaging with mature recycling streams
Clear labelling for efficient disposal
Avoid numerous adhesives, inks or decorations

DfR guidelines are tailored for various packaging formats, and at CIRCPACK, we closely align with RecyClass to ensure that plastic packaging meets these standards, helping to optimise its recyclability. All of our DfR guidelines are available under the glossary found in our knowledge centre.

Yes. You can access comprehensive Design for Recycling guidelines for all packaging formats directly on our website or under the glossary found in our knowledge centre on ReCoRe. For plastics, our guidelines align with RecyClass standards, while all other materials follow CIRCPACK’s proprietary methodology.

These resources are available to help you design packaging that meets recyclability standards and supports sustainable practices.

Some individual countries have developed recyclability schemes and DfR principles that match their local recycling environment [4].

For instance, in Germany, you must comply with the Mindeststandard, a stringent set of criteria that dictates how packaging must be designed to ensure it can be efficiently recycled within the country’s advanced recycling systems. Similarly, in the Netherlands, you need to navigate through the national RecycleCheck program, ensuring your packaging aligns with Dutch standards.

At CIRCPACK, we understand that navigating the diverse landscape of recyclability standards across different countries can be challenging. We have consultants strategically located across Europe, each with deep expertise in the local regulatory environment. This allows us to provide you with tailored advice on how to meet specific recyclability requirements in various markets.

2.2 Certifications

A certification serves as validation of your packaging meeting Design for Recycling guidelines. The certification process itself provides a rigorous assessment of your packaging’s recyclability, offering proof that your materials can be effectively collected, sorted, and reprocessed in a particular market.

Obtaining a recyclability certification for your packaging is important for several reasons. From demonstrating environmental responsibility to ensuring regulatory compliance and enhancing your brand’s reputation, certification enables you to guarantee your commitment to responsible packaging to both consumers and regulators. Additionally, with the upcoming PPWR, your financial obligations may soon be linked to the recyclability grade of your packaging, making certification even more crucial. This becomes even more important when you consider the Green Claims Directive and related topics which increase the requirements associated with making sustainability claims.

CIRCPACK’s team of consultants is uniquely equipped to help you assess and certify the recyclability of your packaging, regardless of the format, ensuring that your packaging meets the highest standards by testing it in one of our Veolia MRFs.

You can get an initial assessment of your plastic or metal packaging’s recyclability using the Recyclass online tool. This tool provides a preliminary score, which you can download as a PDF.

You can then share this report with one of CIRCPACK’s consultants to begin the official certification process, ensuring that your packaging meets all necessary standards.

Module 3: Producer Responsibility

Here we cover essential legal frameworks and responsibilities surrounding packaging and packaging waste. We provide a limited overview of the main laws governing packaging, explain the concept and importance of Extended Producer Responsibility (EPR), and detail the role of Producer Responsibility Organisations (PROs). The module also explores how EPR obligations vary across different countries, helping you understand the diverse regulatory landscape and its impact on your packaging practices.

3.1 Core concepts

Extended Producer Responsibility (EPR) is a policy approach that holds manufacturers accountable for the entire lifecycle of their products, from design and production through to disposal. While EPR can apply to a wide range of products, including electronics, batteries, and vehicles, our primary focus is on packaging, referred to in the UK as pEPR.

EPR is an effective lever because it aims to reduce excess waste, conserve resources, and promote sustainable product design via fiscal levies, alongside bonuses and penalties. By making producers responsible for ensuring that their packaging can be efficiently collected, sorted, and reprocessed for reuse, EPR not only helps to minimise environmental impact but also fosters greater environmental awareness and accountability by driving companies to design packaging which is easily recycled. This approach creates innovation in packaging design, encouraging the development of more sustainable materials and systems that support a circular economy.

A Producer Responsibility Organisation (PRO) is an entity that plays a central role in the implementation of EPR policies. PROs help companies fulfil their EPR obligations by financing the collection, sorting, and recycling of products and packaging at their end-of-life. They also compile essential data for reporting to local authorities, monitor the performance of different packaging formats, and encourage producers to design packaging with recycling in mind.

While they can exist as either competitive for-profit organisations or non-profits, PROs need to manage these responsibilities, ensuring that EPR systems operate efficiently and that producers are supported in meeting their environmental obligations.

Yes. These differences can manifest in various aspects such as the scope of products covered, financial mechanisms, reporting requirements, enforcement and penalties, eco-modulation (which adjusts fees based on the environmental impact of products), and the level of stakeholder involvement.

Each country implements EPR according to its own regulations and priorities, meaning that businesses must navigate a complex landscape of varying requirements. Please keep in mind that the differentiation between EPR fees in Europe is not expected to simplify under the PPWR.

To help you manage these differences, our ReCoRe platform provides detailed information on how each country implements EPR, including the most recent fees where applicable.

Fees are typically used to fund various aspects of the waste management system, ensuring that producers contribute to the environmental costs associated with recovering their products. These fees are directed toward financing the collection, sorting, and recycling of packaging and other products at the end of their life cycle.

For a direct example, think of companies like Amazon and FedEx, where the last mile is the most difficult and often expensive part of delivering a package. The recycling system has the same problem, but in reverse order. For this reason, collection and sorting often match the 80% rule described earlier with the same amount of every Euro earmarked for operations under an EPR scheme.

In addition, EPR fees support the infrastructure needed for effective waste management, such as the development and operation of MRFs and other reprocessing facilities, public awareness campaigns, and environmental education programs. They may also be used to cover administrative costs associated with managing EPR schemes, including compliance monitoring and reporting.

3.2 Local legislation

Packaging and packaging waste are governed by a wide range of laws and regulations worldwide, each with its own specific requirements. Understanding and navigating these varied legal frameworks is crucial for businesses involved in packaging, as compliance not only ensures regulatory adherence but also supports broader sustainability goals and enhances brand reputation across different markets.

All legislation can be efficiently compared by ReCoRe users via our comparison tool.

In the European Union, the foundational legislation has been the Packaging and Packaging Waste Directive (94/62/EC), which has recently been updated and strengthened by the Packaging and Packaging Waste Regulation (PPWR). This new regulation introduces more stringent and harmonised requirements across the EU, focusing on extended producer responsibility (EPR), recycling targets, material restrictions, labelling requirements, waste reduction, and take-back schemes, aiming for a more circular economy.

In North America, both the United States and Canada have a more decentralised approach, with state or provincial-level legislation that works in tandem with federal laws. These regulations address similar themes—EPR, recycling, and waste reduction—but can vary significantly between regions, making compliance a more complex challenge for businesses operating across multiple states or provinces.

The regulatory landscape in AME is diverse and still emerging. Some countries have started implementing EPR schemes and recycling targets, but overall, the region faces challenges related to infrastructure and enforcement. However, there is a growing awareness and push towards more sustainable packaging practices, driven by both international influence and local environmental concerns.

In Latin America (LATAM), packaging waste regulations are evolving rapidly. Countries like Chile and Peru are leading the way with EPR laws and mandatory recycling targets. However, enforcement and infrastructure can vary widely across the region, with some countries still developing their regulatory frameworks.

There is significant diversity in packaging and waste management laws in APAC. Countries like Japan and South Korea have well-established systems with strict recycling and EPR regulations. Meanwhile, other nations in Southeast Asia are in earlier stages of developing comprehensive waste management laws, though there is a growing focus on reducing plastic waste and improving recycling rates.