Marybeth Collins
Every year, billions of units of small-format packaging—such as bottle caps, cosmetics containers, and food service items—are discarded, with most ending up in landfills. Despite their recyclable materials, these small items often evade sorting equipment, contaminating other recycling streams and reducing overall recovery rates. However, new research from the
Center for the Circular Economy at Closed Loop Partners reveals a significant opportunity to recover and reintegrate these valuable materials into the supply chain.
With increasing regulatory pressures, consumer advocacy for sustainability, and corporate commitments to incorporating recycled content, small-format plastics recovery presents a viable solution for businesses looking to enhance their environmental and economic impact.
The Research: Turning Waste into Value
The study, conducted in collaboration with major brands like Maybelline New York, Kraft Heinz, L’Oréal, P&G, and Target, focused on assessing the feasibility of recovering small-format packaging in U.S. materials recovery facilities (MRFs) and glass recycling plants. Through extensive field trials, the research team evaluated equipment upgrades, sorting technologies, and market demand for recovered materials.
Key Findings:
- Economic and Environmental Potential
- Small-format packaging includes valuable materials like polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE), and metals, which have strong demand in secondary markets.
- Diverting these materials from landfills can generate significant revenue, lower landfill costs, and increase the market value of recycled glass by reducing contamination.
- Technological Solutions Exist
- Existing sorting technologies can be optimized to recover small plastics at MRFs and glass plants.
- A 2024 case study demonstrated a 67% reduction in plastic contamination in the glass stream after upgrading a glass screen at a recycling facility.
- Market Demand is Strong
- Mechanical recyclers show high interest in clean, sorted small plastics, often willing to pay more than molecular recyclers.
- 75% of mechanical recyclers surveyed expressed interest in incorporating recovered small-format plastics into their feedstock.
- Investment is Critical
- Recovery efforts require capital investment in equipment upgrades, logistics optimization, and infrastructure expansion.
- Financial support through Extended Producer Responsibility (EPR) programs and brand-led initiatives will be necessary to scale solutions.
Business Implications: A Competitive Edge in Sustainability
For businesses, small-format plastics recovery represents more than just a sustainability effort—it’s an opportunity to drive innovation, reduce costs, and align with consumer and regulatory expectations.
- Regulatory Compliance: With laws like California’s SB 54 classifying small-format plastics as non-recyclable, companies must act to avoid potential fines, market restrictions, or mandatory packaging redesigns.
- Brand Reputation: Consumers increasingly demand sustainable packaging solutions. Proactively investing in recyclability efforts strengthens brand loyalty and differentiates companies in a competitive market.
- Supply Chain Resilience: Increasing the availability of recycled materials can help companies meet post-consumer recycled (PCR) content commitments and reduce reliance on virgin plastics, which are subject to price volatility.
Consumer Impact: Making Recycling More Effective
Currently, many consumers unknowingly discard recyclable small-format packaging due to a lack of infrastructure and awareness. Research findings suggest that regional education campaigns combined with improved recovery systems could significantly increase participation rates.
By ensuring these materials are effectively collected and processed, brands can empower consumers to make a tangible impact on reducing waste and promoting a circular economy.
Next Steps: Industry Collaboration for Real-World Implementation
To accelerate progress, the Consortium for Small-Format Packaging Recovery has been launched, bringing together brands, recyclers, policymakers, and other stakeholders. The initiative aims to:
- Fund and deploy equipment and infrastructure upgrades for rigid small plastics recovery.
- Establish a strong value chain for small-format material recovery.
- Quantify the impact of recovery efforts through data-driven metrics on waste diversion, carbon emissions reduction, and recycled content generation.
