Over two years, 15 industry advisors worked closely with labs, academics and stakeholders to refine the Designing for a Circular Economy (D4ACE) guidelines for polyolefin-based flexible packaging. We sat down with a few of them to hear what stood out from the testing programme…and what comes next.
Interview with Adam Herriott, Senior Specialist at WRAP, a global environmental action NGO – and a key advisor to the ‘Phase 2’ testing project.
Looking back on your involvement, what was one key challenge or knowledge gap the ‘Phase 2’ testing programme helped address, and how has that strengthened the new guidance?
A long-standing challenge has been understanding how seemingly “minor” constituents can shift an otherwise good mono-PE or mono-PP pack from being recyclable in theory to becoming problematic in practice. Phase 2 helped replace assumption with evidence. The testing shows where barrier layers, inks, coatings and adhesives still support recyclability, and where they start to compromise outcomes.
That clarity is exactly what we need in the UK and across Europe. In the UK, the Recyclability Assessment methodology (RAM) classifies packaging based on what current infrastructure can sort and process, not what might be achievable under ideal conditions.
Thanks to the Phase 2 data, we can now calibrate RAM guidance on things like EVOH levels, print coverage and binder systems with much more confidence. The recommended design sequence also makes sense in this context: start with sortability, then mechanical recyclability, then end market suitability.
The next step for us in the UK is to map D4ACE outcomes directly to RAM classifications. That would give businesses a single, joined-up reference point to support UK Plastics Pact targets, minimise late-stage redesign or revalidation, and make pEPR price signals easier to anticipate. Now it’s up to us, alongside CEFLEX and UK stakeholders, to turn this shared insight into practical UK specifications.
“The updated guidance gives firmer boundaries for polyolefin structures that include components like PA, PET, PVDC, EVOH, metallisation, inks and adhesives. That helps specifiers brief suppliers more clearly and make design trade-offs with fewer unknowns.”
From your perspective, what are the most important changes or updates in the ‘Designing for a Circular Economy’ guidance, and why do they matter for industry today?
Three changes really stand out for UK and European businesses.
First, the updated guidance gives firmer boundaries for polyolefin structures that include components like PA, PET, PVDC, EVOH, metallisation, inks and adhesives. That helps specifiers brief suppliers more clearly and make design trade-offs with fewer unknowns.
Second, there is a stronger focus on sortability, not just whether a material can be reprocessed under lab conditions. This is essential, because both RAM in the UK and new EU rules focus on what sorting plants can identify and separate at scale.
Third, the guidance gives a clear preference for mono-PE and mono-PP structures, with restrained printing and compatible barriers. That direction supports the UK Plastics Pact and improves the consistency and quality of recyclate.
In practical terms, I see more teams are starting to use D4ACE, RAM and OPRL together as one design system. Early packaging concepts go through the D4ACE Design Check, then get cross-referenced to RAM classifications, and finally matched with an appropriate OPRL label. That process reduces redesign risk, protects launch timelines and sharpens supplier contracts.
As pEPR in the UK develops and flexible film kerbside collections expand, clear guidance on constituents and sortability is the fastest way to turn targets into real tonnes.
“Adopting D4ACE is the most direct route to regulatory readiness on both tracks. It aligns with PPWR recyclability criteria in the EU and provides the technical backbone for RAM outcomes, OPRL claims and pEPR price signals in the UK.”
In your view, why is adoption of this guidance essential for companies aiming to meet upcoming PPWR targets for recyclability and recycled content – and what additional value does it provide?
Adopting D4ACE is the most direct route to regulatory readiness on both tracks. It aligns with PPWR recyclability criteria in the EU and provides the technical backbone for RAM outcomes, OPRL claims and pEPR price signals in the UK.
The immediate benefit is better design choices that work in sorting and recycling plants, in practice. That grows supply and quality of polyolefin recyclate and supports the UK Plastics Pact on design, effective recycling and recycled content.
There is also real added-value in the openness of the guidance. Transparency in methods, datasets and explainers help packaging engineers and technologists understand the rationale behind each recommendation, which speeds internal adoption and supplier alignment.
Adam Herriott, Senior Specialist at WRAP