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Design for Recyclability

APR Design Guide and CEFLEX guidelines: materials, labels, adhesives, closures, inks. Avoid combinations that block recycling.

8 minutes
recyclability
Next: On-Pack Recycling Labels
Lesson Video
Design for Recyclability
Module Content

1. Executive Summary

Top insights
  1. Match the stream. Design to the dominant recycling stream you target (e.g., clear PET bottle stream vs. colored; HDPE natural vs. colored; films mono‑PE vs. mono‑PP). That dictates what’s “compatible” vs. “detrimental”. [1, 2,3]
  2. Labels & sleeves break good packs. On PET bottles, use floatable polyolefin (PE/PP)labels/sleeves and a hot‑caustic wash‑off adhesive; avoid PETG/PVC sleeves and non‑removable labels. [2, 4]
  3. Adhesive temperature matters. For PET, labels must release in alkaline wash ~60–80 °C leaving no residue. For HDPE/PP rigids, water‑releasable at ~40 °C(no caustic) is recommended to ensure label removal after grinding/washing. [8,16]
  4. Closures should float and be mono‑polyolefin.HDPE/PP closures (no metal parts) that float (< 1 g/cm³) and detach from PET flakes are preferred; tethered caps are mandatory on EU beverage containers up to 3 L from 3 July 2024 (EN 17665 test standard). [5, 19,20]
  5. Inks & colorants: avoid NIR‑undetectable darks.Carbon‑black and heavy dark masterbatches impair NIR sortation; keep direct printing off PET bodies (use the label). [8]
  6. Coverage & mass thresholds matter. High sleeve/label coverage can trigger “problematic” classifications (e.g., UK OPRL flags >60% rigid surface coverage as an issue). [9]
  7. Use recognized test protocols. APR Critical Guidance and RecyClass Evaluation Protocols de‑risk innovations (e.g., new label/adhesive systems, RFID). [4, 14]
Recommended actions
  • Lock mono‑material by design. PET bottle + PO (PE/PP) floatable label + HDPE/PP closure + wash‑off PSA; flexible packs ≥90–95% one family (PE or PP). [2]
  • Specify adhesives by test performance, not chemistry. Require APR Critical Guidance / RecyClass approvalsfor the exact label‑adhesive‑facestock combination in RFQs. [4, 14]
  • Set artwork rules. Ban body printing on PET bottles; restrict dark coverage; avoid metallic foils; define max label/sleeve area by format. [8]
  • Engineer closures to float and pass EU tethering where relevant; choose HDPE/PP; remove liners/springs; validate to EN 17665. [5,19, 20]
Key risks (12–24 months)
  • Harmonization pressure (APR ↔ RecyClass; UK RAM/OPRL alignment) may tighten evidence requirements and change label/adhesive thresholds. [11,14]
  • SUP Directive enforcement drives redesign of EU beverage closures; non‑compliance risks withdrawal from market. [19, 20]

2. Definitions & Concepts

  • APR Design® Guide (US) — Industry guide from the Association of Plastic Recyclers; includes Critical Guidance tests. [1, 4]
  • CEFLEX D4ACE (EU) — “Designing for a Circular Economy” for flexible packaging. [2]
  • RecyClass (EU) — DfR guidelines + Evaluation Protocols and graded methodology (A–F). [3, 14]
  • EPBP — European PET Bottle Platform design rules for PET bottles. [5]
  • NIR sorting — Near‑infrared scanners identify polymers; dark carbon‑black and full sleeves can defeat it. [8]
  • Float–sink separation — Water‑based density step; PO (PE/PP) floats, PET sinks—used to detach labels/closures from PET flakes. [1, 2]
Concept map (bullet view)
  • Target stream → preferred polymer → label/sleeve + adhesive + ink rules → component tests (APR/RecyClass) → sortation (NIR) → wash performance → regrind/flake quality. [1, 2,3, 8]

3. Standards, Regulations, and Governance

Authoritative landscape
  • US: APR Design® Guide & Critical Guidance Protocols (PET, HDPE, PP; sortation/NIR). [1, 4,8]
  • EU: CEFLEX D4ACE (flexibles), RecyClass DfR + Protocols/Methodology, EPBP for PET bottles, SUP tethered caps with EN 17665. [2,3, 5,19, 20]
  • UK: OPRL labelling rules aligned with Defra’s RAM; WRAP design guidance complements. [9,11, 12]
TopicUS (APR)EU (RecyClass/CEFLEX/EPBP)UK (OPRL/RAM/WRAP)
PET body printingDiscouraged; use labels; ink bleed detrimentalDirect printing on PET bottles generally forbidden; retain only essential marksFollows EU/WRAP practice
PET label materialFloatable PO; avoid PETG/PVCFloatable PO; PETG disqualifiesHigh coverage penalized (>60% rigid)
Adhesive releasePET: hot‑caustic; HDPE/PP: removablePET: alkali 60–80 °C; HDPE/PP: water ~40 °CEvaluated via RAM/OPRL tools
ClosuresHDPE/PP float; no metal partsAs left + EU tethered caps (EN 17665)Aligned to RAM criteria
Sortation colorsAvoid carbon‑black/darkSame; RecyClass grading penalizesCommunicated via OPRL classes
Upcoming/ongoing changes
  • APR–RecyClass cooperation continues (e.g., RFID/smart labels, harmonized metrics). [14,21]

4. Evidence Base & Benchmarks

  • PET bottles: Preferred = clear/light‑blue PET, PO floatable labels, hot‑caustic wash‑off PSAs; PETG/PVC sleeves detrimental; keep inks on labels (no body print). [4, 5,8, 17]
  • HDPE/PP rigids: Labels should release in water (~40 °C); adhesives proven by quick‑wash protocols; colored streams tolerate label inks better than PET. [8, 12,19]
  • Flexibles (PE/PP): Aim mono‑material; prefer coex over laminates; adhesives/inks/barriers can affect melt—keep EVOH low; AlOx/SiOx often acceptable (test). [2,8, 19b]
  • Sortation thresholds: NIR failures with carbon‑black/dark surfaces and full sleeves masking the substrate; reduce sleeve area and ensure detectability. [8, 14]
Benchmark hints (indicative)
  • Label coverage (rigids): keep ≤50–60% where possible; higher coverage elevates mis‑sort risk and can downgrade recyclability classes (e.g., OPRL flags >60%). [9, 14]
  • PET label adhesive: fully removable in alkaline 60–80 °C with no residue on flakes/container. [8]
  • HDPE/PP label adhesive: water‑releasable (~40 °C); validated by RecyClass quick wash or equivalent. [8, 12]

Evidence conflicts exist (e.g., exact temperature windows). Follow stream‑owner protocols (APR vs. RecyClass) and require lab evidence for your exact construction.

5. Design & Production Implications

Rules of thumb (by component)
Materials (bodies)
  • PET bottles: clear/light‑blue only; avoid PETG/PVC; keep barriers minimal and approved (e.g., clear plasma coats). [5, 8]
  • HDPE/PP rigids: prefer natural/white; colored okay but reduces value; keep EVOH liners/barriers minimal and tested. [8]
  • Flexibles: mono‑PE or mono‑PP with limited incompatible layers; coex > laminates for DfR. [2,8]
Labels & sleeves
  • PET bottles: use PE/PP floatable labels or sleeves; add perforations for sleeve removal; ban PETG/PVC sleeves. [4,15, 8]
  • HDPE/PP rigids: use releasable labels that detach in water post‑grind/wash; paper labels must not shed fibre. [8, 12]
  • Coverage: cap label/sleeve area and ensure NIR exposure to the base polymer. [8,9]
Adhesives
  • PET: alkali‑releasable wash‑off PSAs (no re‑tack); zero residue on flakes. [8,2]
  • HDPE/PP rigids: water‑releasable at ~40 °C; combinations proven by RecyClass washing tests. [12]
  • Flexibles (laminating): keep total <3 wt% where possible; PU/water‑based acrylics common—test structure‑specific compatibility. [8]
Closures/liners
  • Prefer HDPE/PP closures with no metal parts; liners and springs cause contamination. [5, 1]
  • EU beverages: tether caps to bottle (EN 17665) and keep closure components floatable/detachable from PET flakes. [19, 20]
Inks / colorants
  • Avoid carbon‑black and high‑coverage darks; keep direct printing off PET bodies (ink bleed/discoloration). [8]
Supplier perspective

Provide exact stack‑up (substrate/primer/ink/varnish/adhesive/ liner) and target stream; include APR Critical Guidance or RecyClass approval/report IDs for the specific combination. [4, 12]

Manufacturing notes
  • Shrink sleeves: choose floatable PO and design perforations; PETG sleeves impede both NIR and sink/float. [15, 8]
  • EU tethered caps: validate moulding changes against EN 17665. [20]
Designer tip: Write your label spec as: “Floatable PO facestock + APR/RC‑approved wash‑off PSA; sleeve perforations; label coverage ≤50% body; no carbon‑black inks.” [4, 8,14]

6. Sustainability & Compliance Considerations

  • Recyclability labels: UK OPRL and US How2Recycle implement these technical rules into on‑pack claims; eligibility can depend on label coverage, ink, and adhesive behavior. [9, 17b]
  • Claims risk: “Recyclable” should be substantiated by relevant stream tests (APR/RC) and local collection prevalence (RAM/OPRL in UK). [18, 11]
  • EPR/EU SUP compliance: EU beverage closures must be tethered; failing to comply risks placing‑on‑market issues. [19, 20]

7. Workflow & Tooling (ready to adapt)

Checklists (extracts)
  • Rigid PET bottle: clear/light‑blue? ✓ | PO floatable label/sleeve? ✓ | PETG/PVC avoided? ✓ | adhesive alkali wash‑off @60–80 °C, no residue? ✓ | closure HDPE/PP, no metal? ✓ | body printing absent? ✓ | sleeve perforations? ✓. [4, 5,8]
  • HDPE/PP rigid: label water‑releasable (~40 °C)? ✓ | paper label fibre‑loss controlled? ✓ | dark masterbatch avoided where sortation critical? ✓. [8,12]
  • Flexibles: ≥90–95% one family (PE or PP)? ✓ | coex preferred? ✓ | laminating adhesive <3 wt% and tested? ✓ | AlOx/SiOx only with data? ✓. [2,8]
Decision trees (sketch)
  • If target stream = PET bottle → PO floatable label? → Yes → use alkali wash‑off PSA; No → change facestock → ban body printing → HDPE/PP closure → sleeve with perfs → seek APR CG recognition. [4, 8]
  • If target stream = HDPE/PP rigid → PSA water‑releasable at 40 °C? → Yes → check paper fibre loss → control dark inks → seek RecyClass approval. [8,12]
  • If target stream = flexible PE/PP → mono‑family? → Yes → adhesives/ inks/barriers within D4ACE tolerances → evidence via RecyClass film protocol. [2,14]
Calculator blueprints (to‑be)
  1. Label Coverage % (rigids) = label_unwrapped_area ÷ container_surface_area → flag >50–60% as risk. [9, 14]
  2. Adhesive Mass % = adhesive_coat_weight × label_area ÷ total_pack_mass → flag if PET not releasing at 60–80 °C or HDPE/PP not releasing at ~40 °C. [8]
  3. Float/Sink Check: if component density <1.0 g/cm³ and not attached after wash → expected float (good for PET). [4, 5]
Template RFQ fields (extract)

Target stream + region; component stack‑up; evidence (APR CG/RC report ID); label coverage %; adhesive release temp & media; closure resin & density; ink/colorant class (NIR‑detectable). [4, 3,2]

8. Category‑Specific Guidance (snapshots)

Beverage (PET bottles)
  • Do: PO floatable labels; alkali wash‑off PSA; HDPE/PP closures; sleeve perfs.
  • Don’t: PETG/PVC sleeves; fibre‑shedding paper labels; body printing. [4, 5,15]
Beauty/HPC (HDPE/PP bottles)
  • Do: water‑releasable labels @~40 °C; control dark masterbatch; test laminated toppers.
  • Don’t: non‑releasing labels; metallic foils on body; metal pumps/springs left attached. [8, 12]
Food flexibles (PE/PP)
  • Do: mono‑PE/PP; minimal EVOH; prefer coex; validate AlOx/SiOx coatings.
  • Don’t: unnecessary laminates; heavy PU adhesive loads; dense inks over large areas. [2, 8]

9. Case‑style patterns (condensed)

1) PET beverage: sleeve issue
Switch PETG sleeve to floatable PO with perforations; adopt alkali wash‑off PSA; obtain APR CG report → restored “preferred” recyclability and clear rPET color. [4,15]
2) HDPE personal care: label residue
Move to water‑releasable label validated by RecyClass quick‑wash; eliminate fibre‑shedding paper → improved HDPE regrind MFI stability. [12]
3) Snack pouch: laminate to mono‑PE
Shift PET//PE to mono‑PE coex with AlOx; reduce adhesive mass; pass RecyClass film evaluation. [2,19b]

Evidence gap: open datasets for adhesive residue vs. yellowness (b*) and standardized ink‑bleed rates in hot‑caustic.

10. Common Pitfalls & Red Flags

  1. PET bottles with PETG/PVC full sleeves and no perforation. [15, 8]
  2. PET labels that don’t release in alkali 60–80 °C (flake residue). [8]
  3. HDPE/PP rigids with non‑releasing PSAs post‑wash. [12]
  4. Paper labels that shed fibre (contaminated wash water/regrind). [8, 12]
  5. Carbon‑black or very dark surfaces (failed NIR). [8]
  6. Metal components (springs, balls, foils) attached through recycling. [1, 5]
  7. Flexibles with excess adhesives/inks or multimaterial laminates beyond D4ACE limits. [2]
  8. Over‑coverage labels (>~50–60%) masking NIR signature, especially in UK OPRL context. [9, 14]

Appendix — “Avoid these combinations (fast lookup)”

  • PET bottles: PETG/PVC full shrink sleeves; PET labels/adhesives not fully alkali‑releasing; metallic foils; paper labels that shed; carbon‑black body or full dark sleeves; non‑float closures/liners. [4, 15,8]
  • HDPE/PP rigids: labels + PSA that don’t release in water post‑grind; paper with fibre loss; large area dark inks if NIR exposure needed; metal components in pumps. [8, 12]
  • Flexibles (PE/PP): multimaterial laminates without evidence; high % laminating adhesive; heavy metallic inks; high‑barrier stacks beyond D4ACE tolerances. [2]
Compliance watch: In the EU, tethered caps for beverage containers ≤3 L are mandatory since 3 July 2024; designs must meet EN 17665. [19,20]

References

  1. APR Design Guide Overview — Association of Plastic Recyclers
  2. CEFLEX D4ACE — The Guidelines
  3. RecyClass — Design for Recycling Guidelines
  4. APR Critical Guidance — Clear PET with Labels & Closures (PET-CG-02)
  5. EPBP — Design Guidelines for PET bottles
  6. EU — Single‑use plastics (SUP) page
  7. EN 17665:2022+A1:2023 — Tethered caps test methods/requirements
  8. APR Research — NIR Sorting of Whole Rigid Packages; colorant impacts
  9. OPRL — Rules & RAM alignment
  10. APR–RecyClass Cooperation Report (Mar 2024)
  11. UK GOV — Recyclability Assessment Methodology (RAM)
  12. WRAP — Design guidance for household rigid plastic packaging
  13. APR — PP Rigid (Design Guide)
  14. RecyClass — Methodology 2025 (A–F scoring; sortability & coverage)
  15. APR Shrink Label Working Group — Final Report (2014)
  16. RecyClass — Labels & adhesives on natural/white HDPE
  17. APR — PET Thermoform Packaging Design Resource
  18. How2Recycle — Guidelines for Use (Feb 2024)
  19. APR Design Recognition — Process & Requirements
  20. EUR‑Lex — Implementing Decision (EU) 2023/1060 (EN 17665)
  21. CEFLEX — Designing for a Circular Economy (Dec 2023)
  22. EN 17665:2022+A1:2023 — iTeh Standards entry
  23. APR–RecyClass Cooperation Report (Apr 2025)
Next: On-Pack Recycling Labels