The Impact of Recycled Content Regulations on Polybag Production
In recent years, the global conversation around plastic waste has led to stricter regulations on packaging materials. For manufacturers of polybags and blown film products, this shift is creating both challenges and opportunities. One of the biggest developments is the push for higher recycled content in plastic packaging.
So, what do these regulations mean for the polybag industry, and how can manufacturers adapt? Let’s break it down.
Why Are Recycled Content Regulations Being Introduced?
Governments around the world are introducing laws that require a certain percentage of post-consumer recycled (PCR) plastic in packaging. The goal is to reduce reliance on virgin plastic, cut down on landfill waste, and support the circular economy.
In the UK, for example, the Plastic Packaging Tax introduced in April 2022 applies to plastic packaging that contains less than 30% recycled content. Similar laws are in place or in development across Europe, North America, and other regions.
For polybag manufacturers, this means making big changes to how materials are sourced and how products are made.
How Do These Regulations Affect Material Choices?
Traditionally, polybags are made using virgin polyethylene; a strong, consistent, and cost-effective material. However, to meet recycled content targets, manufacturers now need to incorporate PCR materials into their films.
This switch isn’t always straightforward:
- Quality concerns: PCR materials may have inconsistent colour, strength, or clarity compared to virgin resin.
- Sourcing issues: High-quality recycled plastic can be more expensive and harder to source, especially as demand increases.
- Blending challenges: Adding recycled content to a film formulation requires careful balancing to maintain performance.
Despite these hurdles, innovation is moving quickly. Material suppliers are improving the quality of PCR resin, and machine manufacturers are helping clients adapt with better extrusion controls, web handling, and tension management systems to deal with the new blends.
What Are the Production Challenges?
Integrating recycled content into polybag production isn't just about materials; it affects the entire process:
- Extrusion performance: Recycled materials often behave differently when melted. They may flow at different rates or have variable melt strength, which can impact film thickness and stability.
- Contamination risk: Recycled plastics may contain impurities that can clog filters or cause defects in the film. Good filtration and maintenance routines become even more critical.
- Increased machine wear: Some additives or contaminants in PCR materials can cause faster wear on parts like screws, barrels, and dies.
To address these challenges, many manufacturers are upgrading their blown film lines with advanced process controls, better filtration systems, and more robust web guiding equipment. These investments help maintain consistent quality and reduce waste.
How Can Manufacturers Stay Competitive?
The key to staying ahead is adapting quickly and smartly. Here are a few steps that forward-thinking polybag producers are taking:
- Work closely with material suppliers to test and validate new PCR blends.
- Invest in technology that improves control over tension, thickness, and alignment, especially when dealing with less predictable recycled materials.
- Monitor regulations regularly to stay compliant and avoid penalties.
- Communicate with customers about the benefits of recycled content — including potential cost savings, environmental impact, and compliance benefits.
The Bottom Line
Recycled content regulations are here to stay. While they bring challenges to polybag production, they also open the door to innovation, sustainability, and market differentiation.
By embracing these changes and investing in the right tools and knowledge, manufacturers can not only meet new requirements, they can thrive in a more eco-conscious industry.
If you’re looking to upgrade your web handling or blown film equipment to meet recycled content demands, Swallow Machinery is here to help. Contact us today to learn how our solutions can support your transition.
