Key benefits:

• Commercial and environmental benefits can be achieved when decreasing the unit weight of packaging by reducing packaging and transportation costs (8) and greenhouse gas emissions. For example, since the early 2000s, the average weight of a half-liter water bottle has been halved (1).
• Smartweighting can reduce up to 30% of packaging without impacting recyclability. For example, ALPLA measured a 29% material reduction by lightweighting milk bottles while WRAP reports a 30% material reduction of stretch film used following simple modifications to existing equipment (5).
• Innovative technologies and materials can allow smartweight packaging. For example, alternative thermoforming methods (such as plug assist or explosive forming) can optimize the material flow in the forming dye, allowing for up to 20% thinner films, while lower-density foamed materials such as APET film weigh about 25% less than compacted films (4).

Key cautions: 

• Thinner material does not necessarily mean reduced environmental impact. In particular, consideration should be given to the compatibility of smartweighted packaging with recycling systems since some ultra-lightweight packaging may be so thin that material recovery facilities can no longer sort them, negatively impacting their recyclability. Companies are urged to work with industry experts to better understand the limits of lightweight packaging during sorting for recycling.
• Following recyclability guidelines (e.g., bottle color, label, glue, or ink components) is key to achieving barrier properties, product protection (e.g., rigidity, suitability for transport), and functionality (e.g., allowing for labeling) with materials of reduced thickness (1, 4).