In 2025 RecyClass updated its recommendations on the recyclability of plastic packaging, based on the results of more than 20 testing campaigns. The latest version of the design for recycling guidelines covers all major packaging streams, and in parallel the recyclability evaluation protocols were refined to ensure clarity and repeatability. The changes are intended to reflect real sorting and recycling conditions and to facilitate the shift towards plastic packaging with higher recyclability across Europe.
Paolo Glerean, Chairman of RecyClass, highlighted the importance of relying on robust data: "These new findings reaffirm the importance of continuous, science-based testing to support a truly circular plastics economy." He added: "By refining our Guidelines and Protocols, we are ensuring that design decisions across the value chain align with state-of-the-art recycling conditions in Europe. This is essential to improving material sortability and quality, and boosting market confidence to support the plastic packaging industry in meeting the target of recyclability at scale, as stipulated by the Packaging and Packaging Waste Regulation."
Updates related to sorting and colour
Among the testing campaigns carried out, RecyClass examined the sorting behaviour of metallised decorations and the rolling behaviour of rigid packaging on sorting lines. Given the importance of the sorting stage in the overall recycling cycle, the results of these studies have been incorporated into the updated recommendations.
In parallel, a new colour module was introduced into the sorting evaluation protocol for PET bottles. This is of particular importance for maintaining transparent, clear and light blue material streams within the industry, which are critical for recyclate quality and its further applications.
Recommendations for films and flexible packaging
For flexible packaging, RecyClass published recommendations on the electron beam treatment of PE films and confirmed the full compatibility of PVB-based inks with both PE and PP films. In addition, after two years of testing various ink concentrations, the recommendations on printing on transparent films were revised.
Based on the results of this testing campaign, RecyClass recommendations on the use of inks no longer refer to the surface printing coverage, but instead to the percentage of inks used in relation to the weight of the packaging. This represents an important step towards unlocking the full circularity potential of transparent films, while maintaining compliance with recycling requirements.
Rigid packaging and PET packaging
Additional findings concern direct printing on coloured containers in the HDPE, PP and PS recycling streams. Testing conducted within the PET stream confirmed the full compatibility of PET closures used for bottles, which is relevant for the design of material-homogeneous packaging.
For clear, transparent PET thermoforms, recommendations were developed on sealant layers. Within these, ethylene vinyl acetate (EVA) was classified as fully compatible with PET recycling, while copolyesters were classified as non-compatible. This distinction is important for producers of thermoformed packaging who wish to design products in line with the existing recycling infrastructure.
Continuation of research and industry involvement
RecyClass emphasises that a key element of its activities is the continuous generation of scientific evidence on the compatibility of different packaging features with state-of-the-art recycling technologies. For this reason, new testing campaigns already started in 2026, and more are scheduled to begin later in the year.
To ensure a reliable and harmonised approach to evaluating the circularity of plastic packaging, the organisation stresses the need for broad participation of actors from across the value chain. RecyClass encourages more companies to engage in testing campaigns in order to jointly develop practical, data-driven guidelines for designing packaging with recycling in mind.
