Mono-Material Packaging: Simplifying the Recycling Process
Mono-material packaging refers to packaging made entirely from a single type of material, such as PET, PE, or PP. This singular material approach simplifies the recycling process because the packaging does not need sorting into different material components at material recovery facilities before processing.
Conversely, multi-material packaging is more difficult to recycle and will likely be incinerated or sent to landfills.
Why Mono-Material Packaging Matters
Mono-material packaging is easy to recycle, potentially reducing costs associated with sorting and processing. Mono-materials decrease the risk of contamination in recycling facilities, leading to higher-quality recycled materials.
Mono-material packaging represents a sustainable approach to packaging design, meeting the demands of the circular economy: manufacturing, consumption, recycling, reuse, and remanufacturing. It also helps to reduce waste, environmental impact, and the use of virgin materials.
Brands with mono-material packaging appeal to eco-conscious consumers, providing opportunities to increase sales and enhance customer loyalty.
As regulations increasingly focus on packaging waste and sustainability, mono-material packaging helps companies comply with rules to reduce plastic pollution, lower environmental impact, and promote recycling and recycled content.
However, mono-material packaging presents some challenges. Some products may require the unique properties of multiple materials for optimal protection, shelf life, or usability. Using only a single material may compromise aesthetics and packaging decoration. Transitioning to mono-material packaging may require significant changes in manufacturing processes and supply chains.
Mono-Material Packaging Formats
While most packaging types can integrate mono-material designs, several formats — flexible packaging, pumps, tubes, and caps, especially tethered caps affixed to plastic bottles — are driving adoption.
Only 5% of traditional flexible packaging is recycled, according to the Flexible Packaging Association. That's because of multi-material composite film structures (such as plastic and foil), which most municipal curbside recycling systems cannot handle. However, recent film enhancements like mono-material PE or PP offer improved recyclability.
Berlin Packaging supplies the Sashi refill pouch, a flexible packaging solution with a cap, spout, and film constructed entirely of PE. The mono-material and recyclable pouch comes in 250-ml and 500-ml sizes.
Because of their metal springs and multi-material construction, traditional pump and spray dispensers are typically not recycled. Mono-material pumps and trigger sprayers made of either PP or PE facilitate recycling and offer sustainable packaging options for lotions, liquid soaps, personal care, and cleaning products.
We offer the Future pump, a recyclable mono-material PE dispenser featuring a free-spinning actuator with a unique locking ring. The e-commerce-capable pump meets ISTA-6 Over Boxing testing protocols. Its 2cc output is ideal for viscous products, such as lotions, hair care, and other personal care products. The product comes in a variety of colors to suit individual brand hues.
Single-polymer squeeze tubes, typically made from PE or PP, are gaining traction in the cosmetics and personal care industries. These mono-material tubes are recyclable and replace traditional multi-layer tubes. We offer recycle-ready plastic tubes and can assist with all aspects of tube design and construction, including mono-material (PP or HDPE) tube body/head/closure, diameter dimensions, barrier properties, decorative techniques, and PCR percentages.
Beginning this past July in the EU, all plastic beverage bottles up to three liters must come with a cap that remains attached to the bottle after opening. The regulation spurred advancements in tethered caps, including the development of a clear PET cap for clear PET bottles. Using the same polymer for the cap and container avoids having to separate the two components at recycling centers.
Brands With a Singular Material Focus
Several CPG companies have moved to mono-material packaging solutions to enhance sustainability and recyclability. Here are some examples and case studies.