You must always balance reducing the amount of packaging, changing the materials it is made out of, or enabling it to be reused or recycled, with the need to fulfil a number of key requirements.

Tips for effective product packaging

The first requirement of any packaging is that it meets the needs of the goods it has to carry.

You should:

• ensure that the contents are delivered to the consumer or business user in good condition, whatever stresses it undergoes during distribution and storage
• protect the contents from hazards such as vibration, moisture, heat, odours, light penetration, micro-organisms or pest infestation
• make it easy to open (but difficult to open accidentally) and theft resistant
• allow liquids to pour without spillage
• make it as easy as possible to carry
• make it attractive enough to encourage people to buy the product

Considering product design at the same time as packaging design can help you to keep packaging to a minimum and could offer opportunities for the packaging to be used within the product once it gets to the consumer - see ecodesign for goods and services.

Environmentally friendly packaging tips

If you are designing or redesigning packaging to reduce environmental impacts, you should consider a number of factors including:

• how you can reduce packaging of luxury items while maintaining the product's market value
• what methods you can build into new packaging to ensure the product is tamperproof
• how you can retain sufficient space to carry product information and disposal instructions
• how you can protect the product against damage
• how you can ensure efficient handling and distribution of the product
• any specific needs that a product may need, particularly within the food industry

Packaging must also comply with a number of legal requirements. You should make sure you are aware of these requirements when redesigning any packaging. For more information, see packaging and packaging waste management.

Avoiding packaging wastage

Packaging can be designed to give the product full protection, but often this is not the best environmental option. Assess your packaging to see if there is an acceptable level of wastage and that you are not over or under-packaging your products.

The levels of acceptable wastage your business sets will depend on a number of factors including:

• value of the product
• potential of the product to cause injury or damage
• needs of retailers who may reject an entire shipment if one unit is damaged
• expectations of end customers regarding the packaging of products they buy

To ensure you minimise the environmental impact of your new packaging design, you should consider the product's entire lifecycle. You could seek advice from other organisations in your supply chain to help redesign your packaging.

Product lifecycle and packaging

The lifecycle and the environmental impact of your packaging can be influenced by:

• sourcing materials and energy that reduce the overall materials, energy and waste produced
• keeping the use of hazardous substances to a minimum
• ensuring packaging production and product wastage are reduced
• the distribution methods used by your supply chain
• packaging use and waste options used in your package redesign

To ensure you minimise the environmental impact of your products and packaging across their entire lifecycle, you can carry out a life cycle assessment (LCA).

Make sure you don't focus just on reducing waste and improving the recycling rate of packaging as this could lead to more negative environmental impacts, such as:

• an increase in product wastage or packaging weight if secondary or tertiary packaging has to be used
• a disincentive to use recycled paper and some plastics because they may need to be thicker to provide equal functionality
• more waste for final disposal, even if a very high recycling rate is achieved
• more vehicle movements to deliver the same quantity of product if the packaging is bulkier

Improve the sustainability of your packaging design

Sustainability means meeting the needs of the current generation without affecting the ability of future generations to meet their needs. You can consider sustainability in your packaging design in a number of ways including:

• keeping packaging waste to a minimum
• using materials and energy from renewable sources
• ensuring you have a clear recovery or recycling path after the packaging has finished being used

The raw materials and energy that you use are key components of more environmentally friendly packaging design. You should use renewable resources where possible so that you don't deplete increasingly scarce raw materials.

Wood and paper for packaging

If you require virgin wood fibre, ask your suppliers whether their board comes from fibre sourced from sustainably managed forests. Many forests in Europe now have full certification that states they comply with recognised standards of sustainable management.

Look for suppliers that subscribe to the recognised international standards governed by the Forest Stewardship Council (FSC). The Programme for the Endorsement of Forest Certification (PEFC) scheme provides a framework endorsement programme which also has a set of standards that apply to national forest certification schemes.

You can show that you are using products with fibre sourced from a managed forest by ensuring that they have a 'chain of custody' certificate. This enables you and your customers to trace each stage that the fibre has moved through.

Biopolymers for packaging

Biopolymers are polymers derived from biomass. If you plan to use biopolymers in packaging, you should carefully check the source of the material.

Energy efficiency in packaging production

Ensure that the energy used in the production of your packaging is clean and from sustainable sources.

You should also look closely at your production processes to see whether you can reuse any heat that is generated.

Using recycled materials in your packaging can enable you to cut costs and environmental impact. General principles you should consider include:

• always specifying the technical performance of the recycled material over its actual origin
• adding an element of post-consumer waste and post-industrial (offcut) material as these components count towards your waste packaging recovery targets
• guarding against any potential contamination, especially if your business packages food
• following the Green Claims Code to make it clear what percentage of recycled materials have been used in your packaging

Find more information about green claims.

Types of recycled materials you can use in packaging

With paper and board:

• ensure that all corrugated packaging contains a high level of recycled material
• specify micro-flute board for easier printing
• use high percentages of recycled material in cartonboard in non-food applications
• consider using a laminated cartonboard with some recycled content for packaging food products
• ensure that food product cartonboard is tested for metal contamination

With plastic:

• use the least amount of plastic allowed by your packaging specification
• consider the use of co-extruded plastic bags or containers
• try to reuse any production waste, especially spruces as these are prime materials

With glass:

• if you're importing glass products, specify clear glass as a first option, with brown as a second, as the UK already imports large quantities of green glass
• specify green or brown glass if your products are manufactured in the UK as this will use the supply of cheap glass waste that is constantly available
• consider using plastic shrink sleeves or organic coatings to enable you to use any colour of recycled glass in your packaging

Advantages and disadvantages of recycled materials in packaging

You should carefully assess the use of recycled materials in your packaging design, as in some cases the positive environmental impact may be unclear.

With metal packaging, there are few trade-offs to consider with both steel and aluminium, as they are highly recyclable with no drop in functional performance.

Glass packaging can have a high percentage of recycled content with no drop-off in performance.

Paper and board packaging for non-food contact use should contain high levels of recycled content. However, paper packaging with a high recycled content may have to be heavier than packaging made from virgin fibres as they lose strength each time fibres are recycled, so more fibres are needed to achieve the same level of protection.

Traditionally, plastic packaging has had little recycled content because of the safety risks with food containers. With developments in technology, you can now use some recycled plastics.

Designing your packaging to minimise waste is usually the most cost-effective option and the best for the environment. You can do this in a number of ways.

Techniques for reducing production losses include:

• choosing a package shape that minimises waste material
• using computer-aided design/manufacturing (CAD/CAM) systems to plan more efficient packages or component layouts
• using fewer, larger pack sizes instead of a greater number of smaller ones

Techniques for eliminating packaging include:

• reducing packaging to zero
• eliminating unnecessary layers of packaging
• reducing or eliminating the use of adhesives and tapes
• using embossing or in-mould direct printing to avoid using labels

Techniques for reducing packaging voidspace fillers include:

• reducing unnecessary voidspace in containers - for example where there is a cartonboard pack around plastic inner packaging
• avoiding using fillers - such as expanded polystyrene blocks or bubble-wrap
• considering using air as the packing medium to protect fragile products

Techniques for lightweighting and downsizing include:

• eliminating one or more layers to reduce the overall package weight
• replacing blister packs with cardboard packs
• not using plastic film windows
• using double-walled instead of triple-walled corrugated board when strength is needed
• strengthening individual materials to allow you to reduce overall material use
• reducing the average thickness of the packaging where possible
• using CAD/CAM and associated tools
• avoiding putting strength into secondary transit packaging if this is not necessary

Techniques for reducing energy include:

• using low melting-point adhesives
• considering alternative inks, adhesives or coatings
• reducing the sealing temperature for films

Techniques for improving transport efficiency include:

• choosing packaging shapes that will maximise case and pallet utilisation and transport efficiency
• considering using distribution pack sizes that maximise pallet use and transport efficiency
• adapting packaging to slightly underhang if the pallet dimensions are not exact multiples of the pack dimension

See how to design packaging for easy distribution.

When designing your packaging, there are four key types of hazardous substances your business must be aware of:

• heavy metals - such as lead, cadmium, hexavalent chrome and mercury
• industrial solvents in inks
• coatings and adhesives
• paper-bleaching chemicals

Hazardous substances are usually present in the pigments and other recycled materials that may be used in your manufacturing processes. If your business uses recycled material, you should be careful not to introduce heavy metals - such as lead in glass - during the recycling process.

You can design your packaging to minimise the use of hazardous substances by:

• ensuring your packaging meets the Packaging (Essential Requirements) Regulations limit of 100 parts per million for combined heavy metals
• using paperboard that is unbleached or that only uses a totally chlorine-free or elemental chlorine-free bleaching process
• using inks that have a low environmental impact - such as water-borne, ultraviolet curable and litho inks - instead of organic solvent-borne inks
• considering water-based adhesives instead of solvent-based products
• using the material safety data sheets that suppliers must provide
• using information from the risk assessment you have to carry out under the Control of Substances Hazardous to Health (COSHH) Regulations
• using abridged life cycle assessment software tools - these should take into account the impacts of hazardous substances typically used in generic processes

PVC in packaging materials

Polyvinyl chloride (PVC) is associated with a number of environmental concerns, particularly the release of hazardous substances when it is produced and disposed of. Your business should make a commercial decision whether or not to use PVC packaging in light of the poor image that it has amongst some buyers.

The design of your packaging should take into account how the end products will be transported to their final destinations. As several transport types could be used, you should make sure that the packaging is designed efficiently, but is robust enough to survive what could be multiple journeys.

Packaging and distribution packaging design

You should consider a number of factors when designing new packaging for distribution including:

• how the packaging will contain and protect the contents
• how the packaging will withstand the pressure of stacking
• how the packaging will react to climate changes, vibration and impacts
• ease of handling
• the ability to carry information - such as radio frequency identification (RFID) tags and barcodes
• how effectively space can be used during storage, transport and handling and point-of-sale at retailers
• customers' requests for any special requirements with their packaging

Packaging and transport packaging design

Good packaging design can also have a major impact on the transportation of goods. It is important to design your packaging so that:

• its weight is kept to a minimum
• it can fit into the transport types that will be used
• it is designed to ensure good use of pallets
• it can survive when transported by sea, where goods have more chance of damage

For more information on considering product wastage, see how to ensure your packaging is effective.

Once you have minimised your use of packaging, you should consider whether your packaging can be designed so that it can be reused.

Reuse of packaging which requires the end customer to return packaging to the supply chain - for example glass milk bottles - has been in decline for several years. However, it is possible to have a level of reuse within your business and design packaging that lends itself more easily to reuse. The most common form of reuse for consumer products is of strong packaging that stays with the end user - such as spice jars, biscuit tins or laundry detergent bottles.

You may also be able to reuse packaging within your own business or involve other organisations - such as other businesses in your supply chain.

You should consider whether packaging intended for reuse will actually get reused. For example, you may need to provide refills for people who already have reusable jars, bottles, tins, etc.

There are several aspects of reuse that your business should consider when designing product packaging.

Packaging durability and weight

The options your business could consider include:

• reinforcing existing packaging designs to turn a one-use pack into a reusable system
• ensuring the finish of the packaging can withstand several reuses
• making the packaging lightweight yet durable by using alternative materials

Packaging use and handling

The options your business could consider include:

• ensuring packaging is robust enough to be loaded and unloaded without any significant damage
• making the packaging easy to collapse and stack with clear markings on how the packs should be stacked or nested
• easy opening and secure closing
• easy label removal and attachment to allow reuse

Packaging cleaning and refurbishment

The options your business could consider include:

• designing the packaging so that it can easily be washed ready for reuse
• making the packaging modular and repairable
• ensuring the cleaning process can be completed with the minimum impact on the environment

End of use packaging which is clean and undamaged could be useful for your business or reusable as a resource for other businesses.

One option for your used packaging is to design the packaging so that the end user can recycle it. You can make your packaging compatible with collection and recycling systems by:

• avoiding packaging materials that are not standard and may cause recycling problems
• making your packaging compatible with established recycling processes
• designing packaging that minimises any product residue
• ensuring your packaging can be easily disassembled

Single materials and compatible polymers in packaging

You can increase packaging recycling rates by:

• using corrugated board on its own instead of cardboard that has previously been combined with expanded polystyrene or plastic
• eliminating blister packs where possible
• designing packaging for single polymer use where possible
• identifying polymers in use clearly

Minimising contamination in packaging

You can increase packaging recycling rates by:

• avoiding the use of colourants in plastic packaging wherever possible
• minimising the use of inks, adhesives and other coatings
• minimising the use of labels
• considering making greater use of interlocking tabs on paper
• incorporating moulded press-studs on plastic packaging, hence avoiding the need for adhesives
• using easy-to-remove fasteners rather than tape
• avoiding the use of pressure-sensitive adhesives and cold-seal adhesives on paper and board packaging
• avoiding the use of plastic and foil laminates and ultraviolet varnishes on paper packaging - for example cartons - unless essential

Making contamination easier to remove from packaging

You can increase packaging recycling rates by:

• using recycle-friendly adhesives on paper packaging
• considering using water/acrylic-based emulsions and starch-based coatings on paperboard instead of polyethylene and wax laminates
• using inorganic vapour-deposition coatings that can also be readily recycled - for example those based on silicon dioxide or aluminium oxide

For some types of packaging, the best environmental option may be to design the packaging so that energy can be recovered from the waste materials.

To be classed as 'energy recoverable', packaging must generate more energy than that needed to drive the combustion process. To be sure of this 'calorific gain', the net calorific value must be at least five megajoules per kilogram.

Types of energy recoverable packaging

The following types of packaging are considered energy recoverable:

• packaging composed of over 50 per cent by weight of organic materials - such as wood, cardboard, paper and other organic fibres, starch and plastics
• thin gauge aluminium foil - up to 50 micrometres thick

Packaging consisting of more than 50 per cent by weight of inorganic material - for example ceramic, glass, clay or metals - may be declared energy recoverable if you can demonstrate that there is calorific gain.

The only design consideration is to ensure that any noxious or hazardous constituents of packaging should have a minimal impact on the environment when it is treated to recover energy. The combined concentrations of lead, cadmium, mercury and hexavalent chromium must not exceed 100 parts per million - see packaging and packaging waste management.

For some types of packaging, the best environmental option may be to design the packaging so that the waste materials can be composted. This can only be achieved if the packaging itself is made from completely biodegradable materials.

Your business must also weigh up the use of compostable materials against other environmental goals. Using biopolymers is no better than using other materials in your packaging. You should decide whether using biopolymers has a commercial and environmental benefit.

Compostable packaging checklist

Use the checklist below to help you decide whether to choose compostable packaging.

• Where will your packaging become waste? If it might end up in the home, will the consumer know what to do with it and what are the chances of it being mixed up with material for recycling?
• Is there a high probability that your compostable packaging will be landfilled? Landfilling biopolymers will actually increase the generation and release of methane gas, which is the opposite of what you are trying to achieve.
• Is the product a good candidate for compostable packaging - ie short shelf life, insensitive to moisture or oxygen, does not require heating in-pack and is non-carbonated?
• Will your compostable packaging be lighter or heavier than the packaging it replaces?
• Will the use of biopolymers adversely affect the contents of your packaging?

Find out more about how to produce and sell compost.