Technical innovations and political efforts are leading to increased use of lightweight packaging made from paper and cardboard (P+C) based materials and other cellulose fiber products. Fiber-based lightweight packaging is used in combination with plastics, for example, and often contains residual contamination compared to newspapers and cardboard boxes. Existing P+C recyclers in Switzerland are not specialized in this type of lightweight packaging, which means that it can significantly disrupt the current recycling process. In the conventional P+C stream, this packaging is therefore currently considered waste, as there are no real recycling options.
Subject of investigation
Together with Swiss Recycle, we asked ourselves the following questions:
- What options are available for recycling these fiber-based composite packaging materials in Switzerland?
- Can packaging design contribute to recycling via the existing collection stream for P+K packaging?
- How can the existing high-quality recycling stream of paper and cardboard be maintained?
- Which stakeholders in the value chain need to collaborate to recycle this lightweight packaging?
Approach
In a first step, we analyzed the status quo of existing fiber-based lightweight packaging on the Swiss market. Among other things, we examined its recyclability with the aim of deriving design and system recommendations from the results. We then developed and evaluated ecologically, economically, and socially sustainable scenarios for the recycling pathway. We involved experts and stakeholders along the current value chain in the development of these scenarios in order to incorporate experience from Switzerland and abroad.
results
P+K-based lightweight food packaging in particular has been identified as problematic for existing recycling streams, which is why the focus has been placed on this type of packaging. Compared to the rest of the P+K waste stream, this lightweight food packaging accounts for only a very small amount, although the data available is very incomplete (as of 2025). However, P+K lightweight food packaging almost always has a protective layer that can interfere with the recycling process and is potentially contaminated with food residues, which can lead to various problems in the system. Of eight sample packages tested, only one passed the test for real recyclability. Plastic protective layers or pigmented protective barriers pose particular problems. In addition, the dissolution time in Swiss paper mills is short compared to certain foreign mills, and there are no specialized mills that can handle organic contaminants. However, detailed recommendations to supplement existing guidelines such as 4evergreen could not be derived from the results. This would require further testing and better cooperation with regard to detailed packaging specifications.
Both collection using the traditional P+K collection system and mixed packaging collection (similar to the yellow bag in Germany) currently offer very few ecological advantages over energy recovery. The economic costs and lack of acceptance in society outweigh these advantages, meaning that neither of these collection systems is really suitable at present.
Conclusion
Cooperation between packaging manufacturers, distributors, and Swiss paper recyclers can help ensure that packaging chosen for the Swiss market is theoretically recyclable. The best reference point remains the 4evergreen guideline, which should, however, be supplemented by practical tests.
Ideally, the situation can be reassessed in two to three years, with better data on actual quantities (and quantity trends) and technological advances in sorting and recycling.