A Design for Recycling assessment starts with the right material stream and a complete packaging specification. Check the body, layers, colour, labels, sleeves, adhesives, closures, printing, barriers and residual product before the design is finalised.
Where should a Design for Recycling assessment begin before packaging is submitted for certification?
Start by breaking the packaging down into all its components and assigning the correct recycling stream. Then examine not just the main material, but also every component, decoration and functional feature that could affect sorting, material losses or recyclate quality.
1. Select the correct recycling stream first
Design for Recycling is not one checklist for every type of packaging. RecyClass publishes separate guidelines for individual streams and formats.
A PET bottle, PE film, rigid PP container or PET tray must therefore be assessed against the relevant guidelines. Using the wrong table can lead to an entirely incorrect conclusion.
2. Check the body material and every layer
The main material determines the stream, but packaging can contain layers, coatings, additives or multilayer structures that a superficial assessment might miss.
The specification should describe the actual composition of the structure, not merely a marketing claim such as “mono” or the name of its main polymer.
3. Assess colour and correct sorting
Colour, pigment and decoration can affect packaging identification and the quality of the material stream. Pay particular attention to solutions that hinder optical detection or reduce recyclate value.
RecyClass recommendations differ between streams. Always assess colour in the context of the relevant material and format using the applicable guidelines.
4. A label is not an insignificant addition
A label can affect sorting, washing, separation and recyclate quality. Its material, size, density, colour, attachment method and surface coverage all matter.
Calling a label small or “paper-based” is not enough. Its behaviour in the particular stream must be checked.
5. A shrink sleeve can change the behaviour of the entire pack
A full or large sleeve may prevent the sorting system from recognising the body material and later affect separation and recyclate purity.
If the applicable guidelines do not cover the configuration, or sortability is uncertain, additional testing under a RecyClass protocol may be required.
6. Assess the adhesive together with the label or sleeve
Even an appropriate label material can become problematic if its adhesive behaves incorrectly during washing or remains with the main material.
In some applications, removability under specified washing conditions is important. RecyClass also publishes detailed test protocols for selected types of adhesive.
7. Treat closures, seals and other parts as one system
Caps, closures, pumps, valves, liners and seals can introduce different polymers or materials with different densities and processing temperatures.
A DfR assessment checks whether each part can be separated correctly or remains compatible with the intended recycling process.
8. Printing, inks and decoration also affect recyclate
Print coverage, ink type and decoration method can influence sorting, washing, colour changes and the quality of the resulting secondary material.
“The same bottle with different artwork” should therefore not always be treated as an identical case without checking that proportions and decoration technology remain equivalent.
9. Give particular attention to barriers, additives and multilayer structures
A barrier layer may be necessary to protect the product, but its effect on recycling depends on the material, proportion, structure and stream.
If an innovative solution is not yet described in the applicable Design for Recycling Guidelines, testing under a RecyClass protocol and obtaining a Technology Approval may be an appropriate route.
10. Check emptyability and residual product
Product remaining in packaging after use can introduce additional contamination. Relevant factors include viscosity, geometry, dispensing method and whether the packaging can be emptied in practice.
RecyClass uses an Easy-to-Empty Index approach for selected formats, so packaging functionality should not be overlooked.
11. Design for Recycling is an ongoing process
RecyClass guidelines are living documents. Updates reflect new research, Technology Approvals and changes in knowledge about sorting and recycling.
RecyClass updated guidelines for major streams in 2026. An assessment result should therefore always be linked to a specific document version.
12. Assess DfR before freezing the design
The assessment is most valuable while the label, adhesive, colour, layer or closure can still be changed without restructuring the entire supply chain.
Include DfR as a design review stage during product development, rather than leaving it until an audit is imminent or mass production has begun.
Frequently asked questions
Is a mono-material design enough for a good result?
No. Sortability, colour, additives, decoration, adhesives, residual product and the remaining structural elements still need assessment.
Do Design for Recycling Guidelines stay the same?
No. RecyClass updates them based on research and new technical findings.
Does every innovative component need a Technology Approval?
No. Additional approval may be unnecessary if the solution is already fully covered by the current guidelines.
When is the best time to assess DfR?
During design, before the specification, mould and suppliers are finally fixed.