Modern businesses continually seek ways to reduce their environmental impacts without sacrificing product quality or customer experiences. Many turn to sustainable packaging solutions as a viable method of reducing energy consumption without changing their product formulations.
Post-consumer recycled content (PCR) presents a high-demand alternative to virgin plastic in packaging. Companies have consistently increased the demand for PCR in recent years, and thus far, supply has failed to keep up with rising trends. For packaging designers or manufacturers considering PCR content, exploring the current state of this sustainable material is worthwhile.
What Is Post-Consumer Recycled Content (PCR)?
Post-consumer recycled content (PCR) is the general term for materials made from recycled products that have already been used by consumers. These products may include cardboard boxes, paper, aluminum, plastic bottles, and more.
Local recycling programs collect materials from consumers and then ship them to recycling facilities for sorting. Manufacturers purchase and melt or grind the sorted materials into small pellets before molding them into new items.
PCR can be incorporated into many different materials, such as metals, paper/paperboard, and various types of plastics. It typically cannot be recycled again, reducing the demand on companies to encourage or require consumers to recycle their packaging after use.
Industry Trends and the State of PCR Packaging in 2025
As of August 2024, five states had passed laws requiring the use of PCR in plastic packaging: California, Washington, New Jersey, Maine, and Connecticut. Several other states have implemented Extended Producer Responsibility (EPR) laws to encourage recycling collection. This is in an effort to increase the amount of post-consumer plastic available to be converted into recycled materials.
Various industries use at least partial PCR packaging, such as:
- Food and beverage
- Transportation
- Consumer goods
- Pharmaceuticals
The U.S. market size for PCR plastic packaging is expected to increase from $17.61 billion in 2023 to $47.48 billion by 2033. Collectively, major packaging companies doubled their percentage of PCR use between 2018 and 2021.
While this growth represents a positive step for sustainability initiatives, it has made PCR less available globally. On a broad scale, consumers are not recycling enough plastic to keep up with the demand for this material. The supply of post-consumer recycled plastics today only meets about 6% of demand; additionally, demand is expected to increase by 5 million metric tons by 2030.
For PCR to present a sustainable long-term solution for manufacturers, the current recycling system needs significant improvements. Consumers need to properly clean materials before recycling them so that they can safely be repurposed. They also need to recycle plastic and other materials at a much higher rate than they do now.
Additionally, local recycling programs must accept a wider range of plastics. For instance, few curbside programs accept flexible plastic packaging; consumers are instead required to bring this material to drop-off locations, and participation in these initiatives is low. Today, much of the plastic used in PCR materials comes from businesses, not consumers.
Potential Benefits of PCR in Packaging
The demand for post-consumer recycled content is high for a reason. This material presents a viable solution for packaging manufacturers looking to implement eco-friendly initiatives that do not significantly alter their production or distribution processes.
In many cases, PCR is just as durable as its virgin material counterparts. It can take many forms, replacing materials ranging from paper and cardboard to metal and plastic.
The major benefit of post-consumer recycled content is its lower environmental impact. PCR reduces energy consumption by at least 79% compared to manufacturing traditional packaging materials. It also reduces greenhouse gas emissions by at least 67%. Companies that adopt this material can lower their carbon footprints and instill trust in customers who value eco-friendly practices.
Through its use of reclaimed materials, PCR promotes a circular economy that keeps single-use items out of landfills. It minimizes the need for raw materials, promoting waste reduction and preserving limited landfill space. Companies that use PCR play a small role in conserving natural resources, especially non-renewable resources involved in plastic production.
For packaging manufacturers in one of the five states that have implemented legislation about recycled content in plastics, PCR materials can help them adhere to these laws. Other companies may receive government incentives when they adopt sustainable material alternatives.
Notable Challenges in PCR Packaging
While post-consumer recycled content poses a range of advantages within the supply chain, companies must be aware of the current challenges and potential downsides of this material.
The first revolves around cost. Ideally, PCR packaging would be the same price or cheaper than virgin plastic and other traditional materials. But currently, these reclaimed materials undergo more expensive production. There are costs associated with sourcing the feedstock material, research and development, handling and transportation, and more.
The hope is that the role PCR plays in a circular economy will ultimately lower the price of this material so that it is eventually on par with virgin plastics. But supply and demand also drive price, and currently, demand for this material far outweighs supply.
Post-consumer recycled content sometimes lacks consistency compared to traditional packaging materials. Companies that depend on consistent color, texture, and transparency in packaging may hesitate to switch to these more variable materials. Notably, this downside is mainly aesthetic; the durability of the final material is more consistently reliable than its physical appearance.
Finally, food manufacturers have raised concerns that post-consumer recycled packaging poses a risk of contamination due to the potential for pre-existing food particles and contaminants from unwashed materials. The FDA has implemented procedures to evaluate the recycling processes used within PCR production.
Trayak: Guiding Your Sustainability Journey
Post-consumer recycled content is just one of many sustainable solutions that can reduce the environmental impact of packaging production. Whether this material is right for your company depends on your budget, sustainability goals, industry, and supply requirements. At Trayak, we help businesses like yours navigate their sustainability journeys with easy-to-follow Life Cycle Assessment (LCA) data and expert consulting services. Learn more about our LCA solution, EcoImpact-COMPASS, or our customizable consulting today by calling 513-445-3264.