Sustainable converting
Is modelling change the key to packaging reform?
Modelling and analysis are the key to tackling packaging reform. Phillip Crum, head of data insights at Valpak by Reconomy, explains why.
P
ackaging waste legislation is transforming our industry. From pEPR in the UK to the ambitious goals of the European Union’s PPWR, we are being asked to reach further and do more. While the two regulations diff er in some ways, they share many features, including a fi nancial incentive for brands and suppliers to reduce costs through new designs. For those looking to change, analysis and modelling will make all the diff erence.
WHAT IS THE COST IMPACT? Here in the UK, packaging producers, brands and importers, will soon receive the fi rst pEPR fees based on the new modulated system. With packaging categorised according to PackUK’s Recyclability Assessment Methodology (RAM), ‘red’ non-recyclable packaging will be charged at 1.2 times the ‘amber’ base fee. By 2028, this fi gure will double. Conversely, ‘green’ recyclable packaging attracts the lowest fees, creating clear fi nancial incentives for redesign. As producers look to reduce costs, packaging converters and suppliers will be asked to provide restyled products.
The potential savings through redesign are considerable. Valpak analysis comparing glass sauce jars revealed that switching materials and reducing weight could deliver approximately 26.5 per cent savings in pEPR fees, with some product
variations off ering savings exceeding £10,500*¹. Similarly, lightweighting plastic fruit punnets could bring savings of up to £41,000*² in annual pEPR costs compared with heavier alternatives. PPWR brings a more direct motivation for change. Targets under PPWR include: • By 2030, all packaging must be at least 70 per cent recyclable
• Certain single-use plastics will be restricted • Weight and volume of packaging must be minimised
• Harmonised labels phased in between 2028 and 2029
• Reduction in the use of substances of concern • Certain sectors must meet reuse targets and off er refi ll options
The legislation is extremely complex and demands on businesses vary enormously. For example, a baked goods company selling into Northern Ireland would need to ensure that its boxes reach at least grade C for recyclability, along with the packaging minimisation requirements. Common practices like supplying jam pots with scones are also banned under the rules on single-use packaging. Plastic packaging for foodstuff s must meet the minimum thresholds for post-consumer recycled (PCR) content undergo testing to show that the concentration of PFAS (‘forever chemicals’) is below the maximum threshold.
FOCUS ON COST REDUCTION Valpak’s packaging and product database incorporates over 60 million SKUs. We combine this resource with expert analysis to fi nd the areas that will yield the greatest impact. Not surprisingly, for brands operating in the UK, this means fi nding ways to shift as much material as possible from the ‘red’ category into the ‘green’. Benchmarking allows brands to compare performance against metrics such as the weight, materials and formats of packaging across a particular category, as well as areas like recyclability of packaging and recycled content. It can show businesses where they are performing above average or which areas off er the potential for tangible changes. Environmental impact depends on multiple factors including recyclability, carbon footprint and wider environmental impacts, as well as end-of-life outcomes. When testing a jar of coff ee, for example, switching from glass to plastic appears to reduce costs because, although glass has the lowest pEPR material fee, a high weight leads to a higher overall cost. However, this does not automatically make plastic the more sustainable option.
To fully assess sustainability, businesses should consider conducting an LCA to determine whether packaging changes deliver benefi ts beyond compliance savings. ‘What If’ modelling complements this by allowing businesses to test diff erent hypothetical packaging formats and parameters in their own time.
Investment in change inevitably adds to the cost burden already associated with new environmental legislation. But change is coming and those businesses that get ahead of the game will soon reap the benefi ts. The key to combining a commercial edge with improved sustainability is to analyse, assess and model changes before leaping in. This way, you can balance all your sustainability goals against potential costs, and fi nd the most eff ective outcome for your business.
*¹ Costs have been scaled up according to the total sales quantity of each product in the 2025 half year 1 period.
*² Costs have been scaled up according to the total sales quantity of each product in the 2024 calendar year.
www.convertermag.com
Dec 2025/Jan 2026
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