With nearly 40% of global plastic waste originating from packaging, reducing this waste has become a pressing priority. Post-consumer recycled (PCR) plastic has emerged as a practical solution for sustainable packaging—minimizing landfill use, lowering dependence on virgin materials, and cutting greenhouse gas emissions.
Here, we examine the potential of PCR plastic, its sustainability, benefits, and limitations, and assess its role in the future of sustainable packaging.
What is PCR plastic?
PCR plastic, or post-consumer recycled plastic, is made from everyday items such as bottles, food containers, and packaging that consumers have used and discarded. It primarily comprises polyethylene terephthalate (PET), high-density polyethylene (HDPE), and, to a lesser extent, polypropylene (PP). These materials are collected, cleaned, and repurposed into new products.
How is PCR plastic manufactured?
The process of converting discarded plastics into PCR resin involves several key steps:
- Collection and transportation: In areas with proper recycling systems, consumers deposit used plastics into designated bins. These plastics are then collected and transported to sorting facilities.
- Sorting: At the facility, plastics are sorted by type (e.g., PET, HDPE, PP) using automated systems or manual labor to ensure quality and consistency.
- Cleaning and processing: Once sorted, plastics are washed to remove contaminants, shredded into flakes, and melted to form PCR resin pellets.
- Blending with virgin plastic: Manufacturers mix PCR resin with virgin plastic in ratios ranging from 10% to 100%, depending on the required properties of the final product. For example, if a bottle requires high clarity, it may use 25% PCR and 75% virgin resin to maintain transparency. In contrast, opaque containers can incorporate higher PCR content without affecting quality.
Is PCR plastic biodegradable?
The short answer is no. PCR plastic is not biodegradable. It retains the same chemical structure as traditional plastics, so it does not naturally decompose after disposal. However, its sustainability comes from its recyclability. PCR plastic can be continuously recycled in a circular system, provided it remains free from non-recyclable additives.
What is the difference between PCR and PET plastic?
PCR plastics are made from recycled materials after they are used by consumers, including PET, HDPE, and PP. Once PCR plastic resins are obtained, they are identified as PCR PET, PCR HDPE, or PCR PP, indicating that they consist of reclaimed and processed components derived from used products.
For example, a 100% PCR PET product consists entirely of recycled PET resin. In contrast, PET plastics use virgin materials derived directly from petroleum, which is also used to produce bottles and food packages.
Is PCR plastic the right choice for sustainable packaging?
PCR plastic is increasingly being promoted as a viable alternative in achieving a circular economy. This sustainable approach is primarily beneficial due to its reduced environmental impact, addressing two key issues:
- Waste generation
- Reliance on fossil fuels
For companies, it offers the added advantages of regulatory compliance and improved consumer perception of their products.
PCR plastics reduce environmental impact
PCR plastics help to lower energy consumption and emissions by reducing reliance on virgin plastic production, an energy-intensive process reliant on fossil fuels. Virgin plastics are made from resins derived from natural gas or crude oil. In contrast, PCR plastics help divert waste from landfills and oceans, reintegrating used materials into a continuous recycling loop.
Studies show that using PCR plastics can greatly reduce energy use and emissions, depending on the plastic type which is recycled:
- PET: 79% energy reduction, 67% lower emissions
- HDPE: 88% energy reduction, 71% lower emissions
- PP: 88% energy reduction, 71% lower emissions
Regulatory pressure is driving PCR adoption
Governments worldwide are enforcing Extended Producer Responsibility (EPR) policies to mandate PCR content in packaging. For example:
- Washington state requires PCR content in beverage containers, trash bags, and personal care products, along with annual registration and recycling fees.
- California’s AB 793 mandates tiered recycled content targets, starting at 15% in 2022 and rising to 50% by 2030 under the state’s bottle deposit program.
- Canada’s proposed regulations would require 30-60% PCR resin in plastic packaging by 2030, depending on the product category.
Industries are committing to PCR goals
To meet sustainability targets and consumer expectations, major brands across food, beverage, cosmetics, and consumer goods have set ambitious PCR content goals.
- Coca-Cola: 50% recycled material in packaging by 2030
- PepsiCo: 35% reduction in virgin plastic use by 2025, 25% PCR in plastic packaging
- Unilever: 25% recycled plastic content by 2025
- Danone: 50% PCR content in plastic packaging by 2025, focusing on rPET
- L’Oréal: 50% PCR by 2025, 100% recycled or bio-sourced plastic by 2030
- P&G: 50% reduction in virgin petroleum-based plastic by 2030
Retailers are also mandating PCR use in their supply chains, requiring suppliers to meet minimum PCR content thresholds by 2025.
What are the applications of PCR plastic in packaging?
Due to its adaptability and durability, PCR plastic has been adopted across various industries and is used in a wide range of packaging solutions. Here are some key applications:
Beauty products
Cosmetic brands use PCR plastic for items like mascara tubes, lipstick cases, and serum bottles. This helps reduce plastic dependence while supporting responsible packaging practices in premium product lines. Skincare companies apply this approach to reinforce their values and respond to consumer expectations.
Electronics products
Smartphones, chargers, and accessories are packed in trays and sleeves made from PCR plastic. This packaging helps reduce plastic pollution and addresses electronic waste concerns in global markets. Electronics brands adopt these materials to meet sustainability commitments without compromising durability.
Food and beverage
Containers for ready-to-eat meals, juice bottles, and deli items now feature PCR plastic materials. These containers reduce plastic waste while meeting packaging safety regulations through upgraded recycling processes. Brands use these solutions to meet growing environmental demands in food packaging.
Cleaning products
Detergents, sprays, and multi-use cleaner pouches are increasingly packed using PCR plastic containers. These solutions support responsible waste reduction and encourage the use of refillable product systems. Household brands apply PCR materials to reduce plastic production and support better disposal outcomes.
Medical and healthcare
Bottles, vials, and equipment packaging in healthcare use PCR plastic to reduce medical waste volumes. These items maintain product safety while lowering demand for newly produced plastic packaging. Healthcare brands rely on this method to support clean disposal systems and regulatory compliance.
Key advantages of PCR packaging:
PCR packaging helps reduce plastic waste and supports responsible use of recycled materials. Here are the key advantages of choosing PCR plastic in packaging:
- Waste reduction: PCR plastic helps reduce plastic waste in landfills and oceans. In 2023, the average percentage of post-consumer recycled (PCR) PET used in U.S. bottles and jars rose to 16.2%, increasing from 13.2% in 2022.
- Energy savings: PCR lowers energy consumption by a minimum of 79% and cuts greenhouse gas emissions by at least 67%.
- Encourages recycled materials: Using PCR creates demand for recycled materials, which in turn promotes the development of better recycling systems. In 2023, the U.S., Canada, and Mexico achieved a PET bottle recycling rate of 41.3%, exceeding the global benchmark established by the Ellen MacArthur Foundation.
- Material strength reliability: Properly processed PCR PET can achieve 85-95% of the tensile strength of virgin PET, while its impact resistance typically ranges between 80-90%. Thus, it is a strong and reliable alternative.
- Improve brand image: PCR packaging can improve a company’s sustainability credentials. Research indicates that around 80% of Fortune 500 and S&P 500 companies now publish CSR reports, and many private and smaller businesses are following suit on environmental, social, and economic issues.
Potential drawbacks of PCR packaging:
PCR packaging offers environmental benefits but comes with certain cost, performance, and supply challenges. Here are the disadvantages of using PCR plastic in packaging:
- Higher cost: PCR plastic is often more expensive than virgin plastic due to the collection and processing involved. In late August 2024, in Europe, recycled PET flakes averaged €1,308 per metric ton, €153 higher than virgin resin (€1,155), reflecting a 13.2% premium.
- Less clarity: PCR plastic may have less clarity than virgin plastics. Nonetheless, modern recycling technologies, such as VACUNITE®, now achieve intrinsic viscosity values of up to 0.80 dl/g, matching the clarity of virgin plastics.
- Quality challenges: Ensuring consistent quality can be more difficult with PCR plastic due to variations in recycled materials. One such challenge is color consistency. However, advanced optical sorting with TOMRA’s AUTOSORT® and FLYING BEAM® technology now achieves 99% color separation purity, improving color consistency.
- Limited supply: The supply of high-quality PCR plastic can be constrained by recycling rates and infrastructure. In the U.S., post-consumer recycled resin made up just 9.4% of plastic packaging in 2022, well below the 30% target for 2025.
Is there any difference between PCR and other environmentally friendly packaging?
PCR plastic is an environmentally friendly packaging option, but it is not the only one. Other eco-friendly packaging options include biodegradable, compostable, post-industrial resin, and bioplastics.
PCR vs biodegradable packaging
PCR plastic is made from used consumer products like bottles and containers. Biodegradable packaging, while also aiming to reduce waste, comes from traditional petrochemicals modified to degrade faster. However, it doesn’t always decompose easily or fully in natural conditions, which can lead to partial degradation or microplastic issues.
PCR vs compostable packaging
Compostable materials break down completely under industrial composting standards such as ASTM D6400 and EN 13432. They leave no harmful residue and return to the soil without contamination. PCR plastic does reduce waste and resource use, but it remains plastic, meaning it won’t decompose naturally like compostable alternatives.
PCR vs post-industrial resin (PIR)
Both PCR and PIR help reduce landfill waste. The key difference is the source. PCR uses materials discarded by consumers, while PIR is created from industrial scrap during manufacturing. Since PIR never reaches the consumer, it supports circularity within production, whereas PCR contributes to consumer-level recycling loops.
PCR vs bioplastics
Bioplastics come from renewable resources such as corn or sugarcane and offer an alternative to petroleum-based plastics. However, their disposal can be tricky. Unlike PCR, which fits into existing recycling systems, bioplastics often require separate processing and are frequently mismanaged due to confusion. Many recycling centers do not accept them, and mixing them with traditional plastic streams can lead to contamination.
How can PreScouter help?
PreScouter supports companies in addressing the challenges of sustainable packaging by offering tailored research and strategic insights. Here is how we can help:
- Conducting in-depth market research on PCR and alternative sustainable packaging materials.
- Analyzing the environmental impact and cost-efficiency of various packaging options.
- Identifying reliable suppliers and partners within the PCR supply chain.
- Monitoring and reporting on the latest innovations and regulatory developments in sustainable packaging.
- Assisting with compliance and alignment to evolving environmental standards.
