So, what is sustainable packaging really? “Sustainable packaging” means different things to different stakeholders. For some, it’s about recyclability. For others, it’s about renewable content, circularity, or carbon footprint.
The truth? Sustainable packaging is a systems-level approach that considers the entire life cycle of packaging—from raw material sourcing and manufacturing to use, recovery, and reuse.
True sustainable packaging design is a methodology that takes a full life cycle view from material sourcing and production to use and recovery. At its core, it’s designed to reduce environmental impact without sacrificing functionality or affordability.
Key principles of sustainable packaging include:
Packaging that is safe for people and the environment
Using fewer resources while delivering value and performance
Sourcing materials that are renewable, recyclable, or responsibly recovered
Minimizing energy and emissions during production and transportation
Packaging design that enables reuse, recycling, or composting at the end of life
In short: it reduces environmental burden without compromising safety, performance, or business outcomes.
Packaging makes up over 28% of U.S. municipal solid waste, and plastic packaging is under intense scrutiny from both the public and policymakers. New and emerging legislation, including Extended Producer Responsibility (EPR) laws and Post-consumer recycled content regulations, are shifting accountability back onto producers and brands.
But the value of sustainable packaging goes beyond compliance:
Food packaging companies & brand owners don’t need to overhaul your entire operation overnight to make meaningful progress. However, there are practical steps rigid packaging manufacturers and brands can take starting with design and extending through production and beyond to reduce environmental impact and improve circularity.
Here’s where to start:
Use mono-material structures (like PP or PET) to improve recyclability
Incorporate post-consumer recycled (PCR) content where possible
Avoid Problematic and Unnecessary Materials to avoid unnecessary material changes.
Tip: Look for APR-recognized materials to ensure compatibility with current recycling streams.
Avoid mixed-material structures that can't be separated or recovered
Simplify components — fewer layers, fewer material combinations and eliminate the use of additives & colorants deemed detrimental for recycling
Make sure your design works with current recycling infrastructure, not against it
Tool: Join the How2Recycle® program to help consumers understand how to properly dispose of your packaging.
Reduce process-scrap and cycle times during thermoforming or FFS where possible
Implement energy-efficient systems and closed-loop water use
Evaluate your carbon footprint and look for hotspots in production
Resource: ENERGY STAR and EPA’s SmartWay tools offer benchmarking data and energy-saving best practices.
Optimize wall thickness and geometry to use less material
Reevaluate closures, lids, and container design for opportunities to reduce weight
Balance savings with product integrity, user experience, and transportation durability
Note: Lightweighting is one of the most immediate levers for both cost and sustainability impact—but it requires smart engineering.
Engage with MRFs (materials recovery facilities) to understand sorting limitations
Join coalitions like the U.S. Plastics Pact or Sustainable Packaging Coalition (SPC)
Support education and infrastructure investments that improve rigid plastic recovery
At ICPG, we help brands make the shift to high-performance, recyclable rigid packaging solutions that meet the demands of today — and tomorrow — without compromising food safety, shelf life, or packaging & processing performance. From multi-layer barrier coextrusions to high-performance mono-material structures to customized lightweight designs, we engineer solutions that work for your business and for the environment.
Whether you're responding to new regulations, aiming to meet retailer standards, or building your brand for the next generation of consumers — we’re here to help you make sustainable packaging practical and profitable. Contact us to learn how we can support your goals.