The European Union’s new Packaging and Packaging Waste Regulation (PPWR), effective from February 2025, has set bold sustainability targets for packaging in the next decades. With strict rules on reducing waste, improving recyclability, and incorporating recycled content, packaging designs are under the microscope more than ever. Two popular approaches in designing packaging are mono-material and multi-material packaging. These approaches determine how easy packaging can be recycled and whether it can comply with the new PPWR standards.
In this blog, we’ll dive into the differences between mono-material and multi-material packaging, why they matter in the context of EU PPWR, and how brands can design packaging that not only complies with the new regulations but also supports a circular economy.
What is Mono-Material Packaging?
Mono-material packaging refers to packaging that is made from a single type of material, making it easier to recycle. For example, a cardboard box, a single layer of plastic, or a metal can. These materials can be more easily separated during recycling processes, which leads to a more efficient recycling system.
Under the new PPWR regulations, mono-material packaging is seen as a favorable solution because it simplifies the recycling process. Since the packaging contains only one material, sorting, cleaning, and processing it into new products is straightforward.
Moreover, the PPWR specifies that by 2030, 70% of all packaging needs to be recyclable. Mono-material packaging aligns perfectly with this goal because it is easier to meet the required recyclability standards compared to multi-material packaging.
What is Multi-Material Packaging?
Multi-material packaging combines two or more materials (such as plastic, paper, and metal) to create a more functional or appealing product. For instance, some beverage cartons are made from layers of paper, plastic, and aluminum. These combinations are often used to extend the shelf life of products or improve their durability.
However, multi-material packaging can pose challenges for recycling. The different materials need to be separated before they can be processed, which requires extra steps in sorting and may result in lower recycling rates. As the EU PPWR focuses on increasing recyclability, multi-material packaging faces stricter scrutiny. The complexity of recycling multi-material packaging makes it harder to achieve high recyclability percentages, which is why the regulation is pushing for more mono-material solutions in the market.
The Impact of EU PPWR on Packaging Designs
The EU PPWR brings several new requirements for packaging design, and recyclability is at the forefront. Mono-material designs are the easier choice for achieving compliance with recyclability goals. Let’s take a closer look at some key points from the regulation that impact packaging:
Reducing Packaging Waste
The PPWR mandates that packaging must be minimized, meaning it can’t be larger or heavier than necessary. Starting in 2030, there must be no more than 50% empty space in packaging. This requirement is easier to meet with mono-material packaging, as it is typically simpler to design compact, lightweight solutions using a single material.
Minimum Recyclability Standards
By 2030, 70% of packaging must be recyclable under the PPWR. Mono-material packaging is inherently better equipped to meet this standard. For example, cardboard and PET plastic are easier to recycle compared to composite materials. Since mono-material packaging eliminates the need to separate different materials, recycling systems can more effectively process it.
Recycled Content Requirements
The PPWR requires that by 2030, plastic packaging should contain at least 30% recycled content. Mono-material packaging made from recyclable plastic, for example, is more likely to contain and integrate recycled content, contributing to the sustainability goals set by the regulation.
Reusability
Under the PPWR, at least 40% of sales packaging must be reusable by 2030, and this figure will rise to 70% by 2040. While mono-material packaging may not directly address reusability, it supports a more sustainable lifecycle for materials, making it easier to turn them into new products, which can then be reused in different forms.
The Challenges of Multi-Material Packaging under the PPWR
While multi-material packaging can provide advantages in product durability, protection, and aesthetic appeal, it faces several challenges when it comes to meeting EU PPWR regulations. Here are the primary obstacles:
Recycling Complexity
The biggest issue with multi-material packaging is that it contains layers of different materials that must be separated for recycling. This process requires additional sorting and energy, leading to higher costs and lower recycling efficiency. The PPWR focuses on increasing the recyclability of packaging materials, and multi-material packaging often fails to meet the 70% recyclability target due to its complexity.
Environmental Impact
The inability to recycle multi-material packaging efficiently can lead to more packaging waste ending up in landfills or incinerators. The new EU regulations are aimed at significantly reducing the environmental footprint of packaging. Multi-material solutions are more likely to end up as non-recyclable waste, making it harder for companies to comply with the sustainability goals.
Cost of Compliance
With the PPWR setting stringent recyclability and sustainability requirements, brands that rely on multi-material packaging may face higher costs for meeting compliance standards. This is due to the need for advanced sorting technologies and additional investments in packaging redesigns.
Design Strategies for Compliant Packaging
Given the challenges of multi-material packaging and the growing pressure to comply with the EU PPWR regulations, companies need to adopt design strategies that make their packaging recyclable, sustainable, and cost-efficient.
1. Switching to Mono-Material Packaging
Brands can start by moving to mono-material packaging for most of their products. This could mean using cardboard, recyclable PET, or bio-based plastics that meet the recyclability standards. Mono-material packaging not only simplifies the recycling process but also makes it easier for companies to meet the recycled content and recyclability targets set by the PPWR.
2. Optimizing Packaging Size
Reducing the size of packaging to fit the product better is another way to comply with the PPWR. Automated packaging systems can help brands create right-sized packages that reduce material usage while still protecting the product.
3. Leveraging Recycled Materials
Incorporating recycled materials into packaging is another essential strategy for compliance. Using post-consumer recycled (PCR) content in mono-material packaging helps brands meet the EU’s recycled content requirements and contribute to the circular economy.
Conclusion: The Future of Packaging under EU PPWR
The EU PPWR regulation presents both challenges and opportunities for brands in designing recyclable packaging. While mono-material packaging is the easier route to meet the regulations’ recyclability and sustainability goals, multi-material packaging can still have a place, though it will require more innovative solutions and advanced recycling technologies.
Brands need to act now by adopting eco-friendly practices and transitioning to packaging that supports a circular economy. By designing recyclable mono-material packaging, companies can not only comply with the PPWR but also demonstrate their commitment to sustainability, positioning themselves as leaders in a world increasingly focused on environmental responsibility.