How liners can help food and drink packaging meet recycling and performance goals

Designing packaging that performs on the production line whilst remaining recyclable is a growing priority for food and drink brands. Mono-material caps and containers are becoming more common, but minor components such as liners also play a key role in ensuring recyclability without compromising functionality. Darren Dodd, International Customer Care and Marketing Director at Selig Group, explains how liners can support both recyclability and food-safe packaging performance.

Meeting Regulatory and Sustainability Goals

With regulations such as the Packaging and Packaging Waste Regulation (PPWR) and Extended Producer Responsibility (EPR) driving change, producers are re-evaluating material choices across the packaging lifecycle. One key question is how liners can help “design for recyclability” while maintaining container performance and improving post-consumer recycled (PCR) content in rigid plastic food containers.

The role of minor components

Recyclability isn’t just about the main packaging material. According to WRAP’s polymer choice and recyclability guidance, a package is recyclable if its main components – representing at least 95% of the packaging weight – can be effectively recycled, and any minor components are compatible with the recycling process. In practice, this means that liners, although small, can support or hinder recycling depending on the material choice. They also directly contribute to container durability, lightweighting and sealing performance – all crucial for food and beverage products.

Mono-material Liners for Food Applications

Many food and drink producers are now designing caps, closures and containers from the same material to streamline recycling. Selig’s PP-backed DELTASEAL liner, for example, replaces the original board layer in between two-piece liners with PP foam, allowing easier recycling of PP caps whilst still ensuring reliable sealing for dry and oily food products.

This approach directly aligns with the increasing demand for closed-loop recycling and access to PCR content, helping brands to meet both sustainability targets and consumer expectations.

Boosting PCR Content Safely

Incorporating PCR material reduces the reliance on virgin plastics and lowers greenhouse gas emissions, but in food applications, safety is paramount. Chemically recycled PCR from certified suppliers ensures food contact compliance and eliminates the contamination risks associated with recycling.

Even minor components such as liners can contribute to the PCR content percentage. For example, Selig’s foam based PCR liners contain 15% PCR, based on the total weight of the liner[i]. The PCR induction heat seal liner uses heat seal film that is comprised of 70% PCR and a PET film with 90% PCR and meets the latest FDA and EU food contact requirements. The functionality of PCR content liners remains the same as traditional liners and so there should be no process changes required by producers to make the switch on production lines.

Reducing overall plastic usage

Lightweighting plastic packaging makes sense both economically and environmentally. However, it can create issues with product integrity during transportation and on-shelf. To overcome this, many producers have combined lightweighting with an induction heat seal. In addition, further material savings can be achieved if the liner has been lightweighted too. Take Selig’s Lift ‘n’ Peel™ induction heat seal liner: this has been redesigned to reduce material usage by up to 20%, compared to the original. This adjustment offers consumer brands a more cost-effective and sustainable option, without sacrificing the sealing performance or easy-to-open experience consumers expect.

As the balancing act continues between meeting sustainability targets and packaging performance, liners have their part to play. By offering an ever growing range of solutions that promote sustainable packaging design, Selig Group is helping customers achieve their environmental goals more easily.

[i] Foam based PCR liners (S70 FS 3-19-PCR) – made using the 90% PCR film and are available in a variety of thicknesses to suit a wide range of food and drink applications. When combined with the liner, the total liner contains up to 15% PCR, based on the total weight of the liner.