The Three Sustainable Packaging Paths for 2025

There are only a few real, scalable routes for CPG brands today. Everything else is noise.

Path 1: Recyclable (Mono-Material PE)

This is the direction most brands are moving toward.

Pros:

• Widely accepted by retailer scorecards

• Clear design-for-recycling guidelines

• Compatible with many existing pouch formats

• Works for many, but not all, products

Cons:

• Reduced barrier vs foil or PET laminations

• May require structure redesign

• Not ideal for aroma-sensitive or oxygen-sensitive products

Path 2: Compostable (Limited but Emerging)

Consumers like the idea, but the infrastructure hasn’t caught up.

Pros:

• Strong consumer appeal

• Works for low-moisture, dry products

• Aligns with emerging retail pilot programs

Cons:

• Industrial composting typically required but facilities that take food packaging is almost nonexistent

• Weaker shelf-life performance

• Higher cost

• Not suitable for most mainstream CPG categories

• Barrier versions have undesireable raw materials

Path 3: PCR Integration (Adding Recycled Content)

Post-consumer recycled content is becoming a requirement in multiple states.

Pros:

• Fits EPR expectations

• Strong sustainability story

• Can be used in mono-material structures

Cons:

• Supply constraints

• Potential cosmetic imperfections

• Cost variability

The Barrier Tradeoffs No One Talks About

This is where most brands hit the wall.

Switching from foil to recyclable PE is not a one-to-one swap. Performance changes. Barrier changes. Shelf life changes.

Key challenges include:

• Oxygen sensitivity (especially coffee, snacks, supplements)

• Moisture ingress/egress

• Aroma retention

• Grease and fat migration

• Heat and puncture resistance

This is the part suppliers often gloss over but CPG teams can’t.

Every sustainability move must start with barrier science.

EPR Laws: What’s Actually Coming for Brands in 2025–2026

Extended Producer Responsibility (EPR) laws are shifting real costs onto brands.

States already in motion:

• California

• Colorado

• Oregon

• Maine

More states are drafting similar rules.

What this means for CPG brands:

• You will pay fees based on recyclability and material impact

• You must report packaging tonnage and structure

• “Design for recyclability” becomes a financial advantage

• Non-compliant structures will cost more over time

EPR isn’t theoretical anymore; it’s happening.

Retailer Scorecards Are Quietly Changing Packaging Specs

Retailers are becoming the true regulators.

Walmart, Target, Amazon, and Costco now push suppliers to meet specific sustainability criteria.

Examples:

• Walmart’s recyclability index

• Amazon’s certification for flexible packaging

• Target’s packaging sustainability standards

This pressure often hits faster than legislation and can directly affect shelf placement and vendor approval.

The Admiral Approach: Practical Sustainability That Works

Sustainability only works when the package still performs.

At Admiral Packaging, we combine:

• Material science (to get the barrier right)

• Next-gen flexo print (to maximize shelf appeal)

• U.S.-based supply chain strength (to avoid disruption)

• A dedicated packaging team that engineers structures that truly fit the product

We help brands transition to recyclable, PCR, or hybrid films without guessing, compromising performance, or risking costly rework.

And that’s where we’re built to absorb disruption.

What CPG Brands Should Do Right Now

If you’re planning 2026–2027 packaging roadmaps, here’s the playbook:

1. Audit your current structures
List your barriers, materials, and product sensitivity.

2. Identify which SKUs can move to recyclable first
Start where the barrier requirements are low.

3. Align your packaging plan with retailer guidelines
Scorecards matter as much as laws.

4. Build a recycling-ready or PCR-ready transition plan
Do it SKU by SKU.

5. Test early, test often
Barrier tradeoffs can be devastating to food safety and brand quality.

Get a Sustainability Packaging Audit

Want clarity on what your products need?

We’ll review your:

• Current film specs

• Barrier requirements

• Retail scorecard risks

• EPR readiness

• Opportunities for recyclable or PCR structures

Let's talk to get a sustainability packaging audit and a clear transition roadmap for 2026 and beyond.