June 2, 2025
Recent research is challenging long-held assumptions about the environmental footprint of plastic packaging and other plastic products. A detailed life cycle analysis of polyethylene (PE) packaging reveals that it frequently outperforms other materials such as paper, glass, and aluminum across several sustainability metrics.
For decision-makers in packaging and compliance roles across various sectors, this type of data-backed insight is becoming increasingly valuable to have. Growing regulatory oversight and rising sustainability goals make it more important than ever to think beyond the surface when it comes to selecting materials for plastic products.
Packaging made from polyethylene has been shown to achieve up to a 70% reduction in greenhouse gas emissions compared to packaging made from materials such as paper, glass, aluminum, and steel.
The driving factor behind this difference is in the efficiency of PE throughout its life cycle. From production to disposal, its lightweight composition and lower material requirements translate into lower energy consumption and fewer emissions at nearly every stage.
PE packaging also demonstrates notable advantages when evaluating broader environmental metrics. Water scarcity impacts are often reduced when using PE, as the production process typically consumes less water than competing materials.
In terms of mineral resource conservation, PE outperforms many alternatives due to the relatively small volume of raw materials needed to achieve the same function. Much of this performance comes down to packaging mass; using less material from the start leads to more favorable outcomes across the board.
The life cycle analysis at the center of this discussion examined how PE packaging performs against other common materials such as paper, glass, aluminum, and steel. Rather than focusing solely on abstract metrics, the study evaluated these materials across functional, real-world applications relevant to manufacturing, logistics, and end-use.
For executives tasked with procurement or material selection, this kind of comparison offers tangible insight into which materials deliver meaningful performance advantages under operational conditions.
Across 16 of the 19 comparisons made, PE consistently outperformed alternative packaging materials in terms of greenhouse gas emissions, water use, and fossil resource consumption.
While recycled materials improved results for all packaging types, PE in particular showed continued benefits; however, recycled plastic products sometimes required more material to maintain durability, which slightly diminished their overall efficiency.
The lightweight nature of PE directly contributes to more efficient transportation by reducing fuel consumption and lowering emissions during distribution.
Its durability also plays a role in reducing spoilage and product loss, especially in sectors of food production, agriculture, and consumer packaged goods, where product integrity and shelf life directly impact profitability and sustainability.
The research evaluated the performance of five common polyethylene packaging materials, including shrink films, stretch wraps, and flexible pouches. Each serves a distinct purpose across various industries, offering practical advantages in terms of durability, efficiency, and material savings.
For example, shrink films and stretch wrap play a vital role in stabilizing goods during shipping, while heavy-duty sacks and pouches are valued for their strength and versatility in high-volume or moisture-sensitive environments.
Industries such as food and beverage, personal care, and building materials benefit from PE packaging’s ability to protect products, reduce spoilage, and improve logistical efficiency through lighter loads and compact storage.
Minimizing the use of raw materials and reducing energy consumption throughout the life cycle of packaging is a primary factor in lowering environmental impact.
For business leaders focused on sustainability and achieving greater operational efficiency, these upstream advantages are where material choices make the most measurable difference. Selecting packaging that performs its function with minimal input from the start enables companies to address both environmental and economic pressures simultaneously.
Raw material acquisition and initial processing stages contribute the most to the overall environmental footprint of packaging.
Polyethylene, with its lightweight composition and durability, significantly reduces this impact compared to heavier alternatives. Its efficiency in material use helps lower emissions tied to production while also contributing to cost savings across procurement and manufacturing operations.
Adopting PE packaging as part of a broader sustainability strategy requires alignment between design, procurement, and compliance functions. Life cycle assessment data should be used early in the packaging development process to inform material choices and demonstrate measurable environmental benefits.
For companies operating in regulated markets or focused on their respective ESG targets, PE packaging can support compliance with Extended Producer Responsibility (EPR) programs and improve sustainability reporting. Integrating these strategies helps position businesses to meet stakeholder expectations while building more efficient and accountable supply chains.
The efficiency of polyethylene packaging translates directly into cost savings across the supply chain. Its lightweight nature reduces transportation expenses and fuel consumption, which helps lower overall logistics costs while supporting emissions reduction goals.
Over time, these efficiencies can contribute to reduced exposure to carbon pricing mechanisms and regulatory penalties tied to environmental performance. For companies with ESG commitments, selecting high-performance packaging materials like PE offers a practical way to link sustainability outcomes with measurable financial value and long-term operational resilience.
Staying informed on material innovation and life cycle performance is essential for organizations aiming to lead in both sustainability and competitiveness. As the packaging industry shifts in response to environmental and regulatory pressures, continued engagement with credible industry resources becomes a strategic advantage.
At PLASTICS, we provide members with access to research-driven insights, hands-on sustainability initiatives, and opportunities to participate in shaping the future of packaging standards and other plastic products. Join us today to stay current with regulatory developments, collaborate across the entire plastics value chain, and drive meaningful progress in sustainable packaging.
PLASTICS and the Future Leaders in Plastics (FLiP) Committee are devoted to supporting and encouraging the next generation of plastics leaders who will play a crucial role in the innovation, technology and future of the plastics industry. FLiP’s mission is to provide young professionals under the age of 40 the exposure, education and resources they need to build lifelong careers in plastics. Want to join? Want to get your employees involved? Email: [email protected]
