Recyclable Plastic Trays Proven More Environmentally Friendly Than Laminated Paperboard Packaging
A recent study conducted by postgraduate students from the North East Masters of Science and Engineering program has found that fully recyclable plastic trays, particularly those made with 85% recycled PET (rPET), are a more sustainable food packaging solution than laminated paperboard trays.
While concerns about plastic use remain widespread, the study argues that recyclability and material circularity are more important than simply reducing plastic content. This is especially relevant in food packaging, which plays a critical role in reducing spoilage and waste. The Waste and Resources Action Programme (WRAP) estimates that in 2021 the UK generated 10.7 million tonnes of food waste, with 60% occurring at the household level, largely due to poor storage.
Neil Shackleton, packaging expert and founder of sustainability consultancy Medoola, emphasizes:
“The goal shouldn't just be to reduce plastic, but to choose the right material for the right product and supply chain. For fresh produce and meats, rigid and semi-rigid plastics are often more sustainable, extending shelf life and offering full recyclability.”
🔍 Life Cycle Comparison: rPET vs Laminated Paperboard
Feature | rPET Tray (85% Recycled Content) | Laminated Paperboard Tray |
Material | Recycled PET plastic | Virgin paperboard + LDPE plastic lining |
Recyclability | High – fully recyclable | Low – difficult to separate materials |
Carbon Emissions | Significantly lower | Higher due to virgin material use |
End-of-Life | Recycled and reprocessed | Typically incinerated or landfilled |
The PackFlow Refresh 2023 Report by Valpak reveals that 63% of rigid plastic packaging is recycled in the UK, while composite fiber packaging like laminated trays has virtually zero recyclability.
The Green Alliance's "Plastic Promises" report highlights that many major retailers have shifted away from plastic under public pressure, often without considering whether alternatives are truly more sustainable. Retail executives interviewed in the report admitted that some changes may have increased their packaging's carbon footprint.
The study's life cycle assessment revealed that laminated paperboard trays, though containing less plastic, are made from virgin paper and LDPE plastic, which are energy-intensive to produce and non-recyclable in most existing waste systems. In contrast, rPET trays utilize post-consumer recycled content, are fully recyclable, and align better with carbon reduction targets.
✅ Key Findings:
• rPET trays generate significantly fewer CO₂ emissions.
• Paperboard trays involve high-energy pulping and chemical processes.
• Laminated trays usually end up in landfill or incinerators.
• rPET trays are widely recyclable, supporting circular economy goals.
A consortium of industry players including iPac Packaging Innovations and Pakway, both certified under BRCGS global standards, has backed the findings. The group, known as RPETS, advocates for recyclability-first strategies in packaging design.
Jonny Catto, Managing Director at iPac, commented:
“There's a major misconception that all plastic is inherently unsustainable. This research clearly shows that recyclable plastics like rPET are part of the solution, not the problem. Laminated paper trays may appear greener but often cannot be recycled at all.”
Jeff Brunskill, Managing Director at Pakway, added:
“This study should be a wake-up call for the packaging industry. We need practical solutions that work within real-world recycling infrastructure—not just packaging that ‘looks’ sustainable.”
🌍 Conclusion
The research underscores the need to evaluate packaging sustainability based on recyclability, recycled content, and lifecycle emissions—not just plastic reduction. rPET trays offer a real-world, effective path toward sustainable packaging and support the development of a true circular economy.
🔗 Source: Food & Drink Technology