Welcome back to the Crazy About Packaging podcast! In Episode 10, the Cap Pack — Natalie, Mike, and Jonathan — dig into a topic we’ve seen from every angle: what it really takes to replace packaging material in today’s dynamic environment.
There are plenty of reasons a company might want to make a switch. Regulations change, sustainability targets evolve, performance in the field doesn’t meet expectations. But whatever the reason, one thing is always true: it’s not simple. In this episode, we break down the challenges, the risks, and the smarter way to approach a project that has a lot riding on it.
Sneak Peek for Episode 10
Catch the full episode on Spotify, Apple Podcasts, or our website. Below, we’ve shared some of the highlights, including common drivers that push companies to replace packaging materials, what makes it so difficult, and how we help companies manage it without unnecessary disruption.
Can I Recycle That?
This month’s episode kicks off with the return of a fan favorite game: "Can I Recycle That?"
Natalie brought out a cottage cheese container with an injection-molded polypropylene cup, shrink sleeve label, and foil lid and challenged Mike and Jonathan to figure out its recyclability.
We discussed what the markings on the bottom of the container mean, how to spot injection-molded parts, and what needs to happen to make the whole item recyclable. The final answer? Yes, the container itself can be recycled if you remove the shrink sleeve and throw away the foil lid. The catch is that this kind of multi-component packaging still creates confusion for most consumers, especially when it lacks a "how2recycle" label.
It also tied directly into our main topic: this is exactly the kind of packaging that used to be made with polystyrene. Many dairy products, from single-serve yogurts to multi-pack cups, have transitioned to polypropylene over the years. It's a good example of a successful material replacement that maintained performance while improving recyclability. And with that, let’s explore some of the finer details of material replacement.
Why Do Companies Replace Packaging Materials?
No one starts a packaging project expecting to change materials a few years later. But unexpected pressures often force a rethink and, ultimately, sometimes a change becomes unavoidable. Here are a few reasons we’ve seen manufacturers make the switch:
- Regulatory shifts, such as polystyrene bans or new extended producer responsibility (EPR) rules
- Internal or industry-driven sustainability goals
- Cost pressures, from resin pricing to process inefficiencies
- Performance issues discovered after a product reaches the market
- Competitive insulation strategies to protect proprietary formats
Why Material Change Is More Complex Than It Sounds
Swapping one material for another is rarely straightforward. Packaging equipment is often designed for one resin, and changes to the material can affect forming, sealing, cutting, and more.
Jonathan explains that switching from polystyrene to polypropylene can require new tools, trim systems, and line recalibration. In form fill seal setups, modifying one line might mean investing over a million dollars in equipment alone.
But that’s just one piece of the puzzle. As Mike points out, "You've got to align procurement, operations, quality, sustainability, and regulatory teams. Each has different priorities. That’s what makes it complicated."
It’s Not Always Plastic to Plastic
While many material changes happen within the plastic category, that’s not always the case. Some companies are looking at molded fiber, pulp, or paperboard options. These bring up additional considerations: Will the material hold up under heat? Is it sealable with existing lidding? Will it affect how consumers experience the product?
And sometimes, a switch that seems greener at first glance doesn’t turn out to be better in practice. As discussed in a recent episode on life cycle analysis, regional infrastructure plays a big role.
That’s why we always tell people: it depends on your application, your line, and your goals. Every decision needs context.
How We Help Clients Successfully Replace Packaging
We’ve supported dozens of packaging transitions, and we bring that experience to every project we take on. Our role isn’t just to supply material. We help clients think through every angle and avoid costly surprises.
Here’s what we consider when identifying the right fit for a material change:
- We run material trials on full-scale production equipment, not bench-top lab setups
- We bring real-world converting experience to help validate decisions faster
- We don’t just talk to one team — we help connect procurement, engineering, sustainability, and more
- We’ve built strong partnerships with upstream and downstream collaborators
Jonathan said it best: "We’re not just offering materials. We’re filling in gaps, giving teams what they need to make decisions faster and with more confidence."
Tips for Teams Planning to Replace Packaging Material
Finally, the CAP Pack is happy to share advice we’d give any company starting down this path. Here’s what stood out:
- Start before you’re forced to. These changes take time. Some changes take upwards of a year! The last place you want to be is stuck in a rushed replacement.
- Get aligned on the goal. Know what success looks like. Is it cost-neutrality? Recyclability? Better performance? Get clarity before you begin.
- Bring everyone in early. This isn’t a one-person project. Make sure your internal teams are aligned and talking to each other before materials start running on the line. Mike’s biggest takeaway? "The companies that do this well bring in their supply chain, their resin partners, even end users. The more voices aligned at the start, the better the outcome."
You Don’t Have to Do It Alone
Changing packaging materials is one of the most involved, expensive, and technical things a packaging team can take on. But it’s also an opportunity to reduce costs, meet sustainability goals, or improve performance. And with the right partner, it doesn’t have to be painful.
We’ve been through it. We’ve helped others through it. And we’re here to support your team when you’re ready.
Thanks for listening to this episode of Crazy About Packaging. If you’re thinking about a material change, let’s talk. Connect with us at ICPG or follow us on LinkedIn and Instagram to keep the conversation going.
See you next month.
