Repak Plastic Packaging Design Summary Guide (1) - Flipbook - Page 1
Plastic Packaging Design
Summary Guide
Repak plays a central role in improving the ef昀椀ciency and optimisation of Ireland’s
packaging journey, from design through to recycling. Working with over 3,500 Members
across Ireland to promote a circular economy of reduce, reuse, re昀椀ll and recycle.
Plastic Packaging Design
Considerations
Did yo
know?u
It’s important for producers to consider all aspects of plastic packaging choices as design
will affect reusability, 昀椀nal recycling process and the level of EPR fees paid. This summary
guide provides guidance on best practice across all aspects of plastic packaging design.
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Best Practice
Material
Selection
Colour &
Transparency
Labels &
Sleeves
Closures
& Caps
Additives &
Barrier Layers
Avoid
ere
rn mo
re.
• Use widely recyclable, single polymers
such as PET, HDPE, or PP
• Multi-material laminates that cannot
be separated
• Design packaging using one polymer
wherever possible
• Polymers with low recycling rates
(e.g., PVC, certain PS formats)
• Opt for clear or light-coloured plastics
• Carbon black or very dark colours
(dif昀椀cult for sorting equipment to detect)
• Use minimal pigments to support optical
sorting systems
• Choose colourants that are compatible
with recycling streams
• Heavy or opaque pigmentation that
downgrades recycled material quality
• Use minimal, easily removable recyclable
labels aligned with EU labelling requirements
• Full-body shrink sleeves that hide the
base material
• Select recyclable or compatible label
materials, that match the item it’s going on
• Permanent adhesives that contaminate
recycling streams
• Ensure adhesives are water or alkaline
soluble and can wash off easily during
processing
• Labels made from incompatible plastics
• Design caps and closures from the same
material as the container
• Mixed-material closures that are dif昀椀cult
to separate
• Use tethered caps where possible
• Metal or silicone components that
complicate recycling
• Ensure closures are recyclable within
existing systems
• Misleading or unclear disposal labelling
(now regulated under EU rules)
• Small detachable parts that can be lost
during sorting
• Minimise use of additives, coatings, and
barrier layers
• Multi-layer structures (e.g., plastic and
aluminium laminates)
• Choose additives proven to be recyclingcompatible
• Additives that degrade recycled plastic
quality
• Oxygen barriers or coatings that cannot
be processed
Packaging
Minimisation
& Waste
Prevention
• Design packaging to be easily separated
into recyclable components
• Complex, bonded multi-component
structures
• Ensure shapes and formats are recognised
by automated sorting systems
• Over-packaging or oversized formats
• Reduce material use while maintaining
performance (lightweighting)
• Eliminate unnecessary or excess packaging
in line with EU waste prevention goals
• Design for reuse where feasible
• Single-use formats that are restricted
under EU legislation
