US Plastics Pact sets new guidelines for circular packaging design

The US Plastics Pact, an industry- supported nonprofit, has released updated guidelines for designing reusable, recyclable, and compostable packaging in the US. 

The three handbooks for Recyclable, Compostable, and Reusable Packaging Design outline the latest certification requirements, labeling rules, and guidance for packaging designers, engineers, retailers, distributors, and policymakers. 

“Creating a circular economy requires clear guidance that organizations can use to make informed decisions,” says Marcu Alexander, director of Strategy and Engagement at the US Plastics Pact. 

“These handbooks equip companies with the information they need to incorporate circular design principles into packaging for reuse, recycling, and composting. By fostering greater consistency across the plastics value chain, they can help accelerate progress toward a more circular economy.”

The US Plastics Pact says that the handbooks highlight how packaging is “one of the most powerful levers for improving circularity,” suggesting that “successful outcomes” depend on collection access, end-market demand, consumer participation, and supportive policies. 

However, there are some in the sector that also point toward packaging material as the key to emboldening circularity, with paper and bio-based materials taking center stage. 

Recently, the Publications Office of the EU released a study co-authored by the German Nova-Institute concluding that bio-based plastic packaging can support the climate-neutrality goals of the PPWR. Yet some noted the chemical safety considerations associated with bio-based plastics.

Meanwhile, DS Smith and Yangi have advanced fiber-based solutions for product protection as viable alternatives to single-use plastic packaging. 

Designing for recyclability

The Recyclable Packaging Design Handbook explores how packaging design decisions can affect recycling performance across the supply chain. It encourages brands to align design with the Association of Plastic Recyclers (APR) Design Guide and incorporate post-consumer recycled content where appropriate. 

As the EU’s Packaging and Packaging Waste Regulation (PPWR) looms closer — requiring all packaging on the European market to be recyclable by 2030 — and EPR schemes take off around the globe, brands are increasingly pressured to design for recycling and include recycled content within packaging types. 

Reusable viability 

The Reusable Packaging Design Handbook evaluates research, pilot programs, and practical experience from reuse systems. As consumers and regulations alike challenge the dominance of single-use plastic packaging in the industry, reuse and zero-waste systems are becoming increasingly viable market options. 

Recently, Suri, a personal care product provider based in London, UK, launched a toothpaste featuring a reusable, custom-designed pump and plant-based refill that are said to be home-compostable after use. 

Meanwhile, Lola Valentina, a US-based design and linen rental company, adopted a reusable packaging system developed by Returnity and FedEx that ships products within existing parcel workflows using reusable formats.

Scaling compostables

The third handbook, on compostable packaging design, underscores that compostable packaging should be developed in line with American Society for Testing and Materials standards and stringently verified by third-party certification. 

In May, Packaging Insights sat down with Megan O’Brien, program manager for Policy and Reporting at the US Plastics Pact, to discuss its recent report, Enabling Composting at Scale, which outlines policy frameworks and investment opportunities for stakeholders to increase the longevity of compostable materials in the US. 

“Food waste is often generated alongside packaging, making separation from conventional plastics difficult, especially in settings like foodservice, takeout, and large events,” she said.

“Compostable packaging can help capture heavily food-contaminated materials that are not suitable for recycling by allowing food and packaging to be collected together.”