Design for Recycling: strategic preparation for the PPWR

The new EU Packaging and Packaging Waste Regulation (PPWR) – Regulation (EU) 2025/40 of the European Parliament and of the Council of 19 December 2024 – will be phased in from 2026 and will have a major impact on packaging design, material choices, recycling, and reuse. For companies in the food, consumer goods, and packaging industries, it makes sense to start preparing now.

Why act now?

Early action offers significant advantages. It provides a head start on compliance, avoiding last-minute changes later. It also allows for a phased approach, making structural adjustments in R&D, material selection, and procurement more manageable. Early insight into gaps and improvement areas helps control costs by testing alternative materials or concepts before customers, retailers, or authorities enforce changes. Financially, it pays off too: complex or poorly recyclable packaging will soon become more expensive due to higher taxes and limited recycling options. A proactive approach also strengthens access to major retailers already demanding circular packaging and sustainability reporting, while enabling innovation and marketing benefits through eco-design claims and subsidies.

What is Design for Recycling?

Design for Recycling (DfR) means designing packaging so it can be effectively recycled within existing or future recycling infrastructures. Under the PPWR, packaging will be assessed on parameters that directly influence the quality of recycled output. Key aspects include material choice—mono-materials like PET and cardboard are easier to recycle than composites—plus colour and ink, as light or transparent packaging is more suitable for recycling. Adhesives, labels, coatings, and physical structure also matter, as complex or multi-layer designs hinder recycling. Reuse and circularity options are also considered, as they extend material lifespan and reduce environmental impact.

How to assess recyclability

Companies can assess recyclability by conducting an internal analysis of materials, layers, coatings, and labels, comparing them against national and EU criteria. This reveals how much of the packaging actually returns to the recycling stream and what can be improved to boost efficiency and quality. Digital tools and checklists from recyclers and research institutes can provide a score or indication of recyclability.

Differences across EU countries

It’s important to consider differences between EU member states, as recyclability depends heavily on local collection systems, sorting capacity, and processing facilities. A package that recycles well in the Netherlands—such as PET bottles—may be less efficiently processed elsewhere. Mapping how packaging performs against PPWR now enables strategic choices that work across markets and secure future compliance and market access.

The strategic advantage of early DfR implementation

Early implementation of Design for Recycling offers more than compliance benefits. It helps companies manage costs and materials efficiently, drive innovation, and strengthen their position with retailers and consumers. In short, it’s not a luxury; it’s a strategic necessity for all businesses producing, distributing, or using packaging within the EU.