Design for Recyclability Guidelines (D4R) for packaging containing aluminium
Guidelines for the design of packaging that contains aluminium are essential to ensure that this valuable material is used in a way that supports both functionality and sustainability. Well-structured design-for-recyclability principles help to maximize recovery rates, reduce environmental impact, and harmonize packaging solutions with circular economy objectives.
At the same time, aluminium offers unique advantages that make it indispensable in modern packaging: it is lightweight, provides an excellent barrier against light, moisture, and oxygen, and can be recycled endlessly without loss of quality. These properties not only preserve product safety and quality but also contribute to efficient resource use. Therefore EAFA, together with European Aluminium, Aluminium Closures Group, Metal Packaging Europe, etma and AEROBAL, has commissioned clear design guidelines that unlock its full potential within sustainable material cycles.
Aluminium packaging comes in many forms – from containers, trays, capsules, and foils to pouches or beverage cartons where aluminium plays a smaller but vital role. While aluminium is widely seen as highly recyclable, not every format achieves good recyclability due to design choices or gaps in infrastructure.
The PPWR (EU Packaging and Packaging Waste Regulation) as of January 2025 requires all packaging placed on the EU market to be recyclable by 2030 at the latest. The D4R guidelines give relevant information and recommendations to packaging designers how to improve the recyclability of packaging predominantly made of aluminium. In addition, reference is also made to packaging formats in which aluminium is only a minor constituent or component.
The guidelines were developed in close alignment with PPWR provisions and terminology. They build on Europe‘s advanced collection, sorting and recycling systems (TRL 9) and apply a criteria-based, engineering-driven methodology. This ensures transparent and understandable outcomes.
Practical recommendations for different packaging formats
The guidelines include specific recommendations to improve recyclability for, among others:
- Aluminium trays for convenience food
- Pet food trays
- Aluminium-based coffee capsules
- Alu-alu blister packs
- Cheese and chocolate foils
- Aluminium lids on plastic cups
- Household aluminium foil
- Aluminium closures for wine bottles