Mill Survey Drives New Polycoated Paper Recycling Design Guide

The Poly Coated Paper Alliance has built its new design guidance for mill recyclability on survey responses covering 90% of domestic consumption at white fiber and brown fiber mills.

The guidance, which PCPA says addresses a gap in the market and aligns with extended producer responsibility policies in the U.S., draws on input from white fiber (grade 52) and brown fiber (grade 54) mills, explained Joel Schoening, senior consultant with RRS, which helps manage PCPA. Responses were weighted based on the proportion of consumption from each mill.

PCPA laid out a four-tier rating system for packaging design choices: compatible, conditionally compatible, not compatible, or unknown. "Conditionally compatible" could mean only some mills accept a material, or that mills accept it only in certain quantities.

The Poly Coated Paper Alliance launched in 2023 and comprises paper and packaging companies, brand owners and partner groups. Recycling options for certain polycoated paper items, such as cartons, have drawn particular scrutiny as state policy evolves.

Schoening said PCPA reviewed comparison design guides for fiber and other materials before building its own. The group describes the new resource as "the first comprehensive U.S. design guide developed specifically for poly coated paper packaging."

"The guidance should be considered from the perspective of where a packaging designer would want or expect their product to flow," Schoening explained.

Access remains limited for now. The guidance is available only to members, but the group expects to release it publicly in a matter of months, according to Schoening.

PCPA is also engaging with Circular Action Alliance — the producer responsibility organization helping implement California's EPR and source reduction law SB 54 — to see whether the guidance can be included in the next California program plan.

The findings already challenge some assumptions about material acceptance. Wet-strength additives have been a concern in some states, but through the guidance development process PCPA identified compatible and conditionally compatible wet-strength options for both white fiber and brown fiber mills, Schoening said.

PCPA's leadership includes RRS, the Carton Council, the Foodservice Packaging Institute, Graphic Packaging International, Sonoco, Mars and Procter & Gamble. Additional participants include Campbell's, Domtar, General Mills, Kraft Heinz, PepsiCo, Smurfit Westrock, Sustana, Toppan and others.

For packaging designers at CPG brands, the practical takeaway is a mill-tested framework for material choices. If Circular Action Alliance incorporates the guidance into California's next program plan, the ratings could carry direct financial consequences under SB 54 compliance.