LCA Study: Mono-Material vs Traditional Packaging
Comparative Life Cycle Assessment on flexible packaging for coffee, dried fruit and cheese. Published in Environmental Impact Assessment Review after international peer review.Poplast has conducted a comprehensive LCA (Life Cycle Assessment) study on traditional and mono-material flexible packaging structures for three food applications: coffee, dried fruit, cheese.
The study, carried out in collaboration with CIPACK – Interdepartmental Packaging Centre at the University of Parma (Prof. Giuseppe Vignali, Eng. Roberta Stefanini) and the Poplast R&D team (Eng. Gian Marco Ricci), applies the ISO 14040/14044 methodology and the Environmental Footprint (EF) 3.1 method with a cradle-to-grave approach.
Results: CO2 Emissions Reduction
The results demonstrate a significant reduction in CO2 equivalent emissions across all applications analysed:
COFFEE (1 kg) |
DRIED FRUIT (0,2 kg) |
CHEESE (0,2 kg) |
|---|---|---|
-68,5g CO2eq (-44%) |
-9,6g CO2eq (-25%) |
-3,9g CO2eq (-11%) |
Structures Compared
The study compares traditional multi-layer structures with mono-material alternatives for three food categories:
Application |
Traditional (multi-layer) |
Poplast Mono-material |
|---|---|---|
Coffee |
PET/AL/PE Not assessable (aluminium) |
PP/PP cast Class F Recyclass |
Dried fruit |
OPA/PE Class F Recyclass (not recyclable) |
MDOPE/PE Class B Recyclass |
Cheese |
PET/PE/EVOH/PE Class F Recyclass (not recyclable) |
PPHB/PP cast Class B Recyclass |
Note: All structures guarantee equivalent shelf life to traditional solutions.
Methodology: ISO 14040/14044
The study applies international standards ISO 14040:2006 (Principles and framework) and ISO 14044:2006 (Requirements and guidelines), using:
- Calculation method: Environmental Footprint (EF) 3.1
- Software: SimaPro 9.6
- Database: Ecoinvent 3.10
- Approach: Cradle-to-grave
- Categories analysed: 10 environmental impact indicators
System boundaries
- Raw material extraction and production (40-80% of total impact)
- Transport and procurement from suppliers
- Poplast manufacturing processes (printing, lamination, slitting)
- Production waste management
- Packaging end-of-life (recycling/incineration/landfill)
End-of-Life Scenario: Recycling vs Incineration
The environmental advantage of mono-material solutions derives mainly from the end-of-life phase:
Mono-material (Class B) |
Multi-layer (Class E/F) |
|---|---|
83% recycling 17% landfill Closed-loop recycling possible |
83% incenerimento 17% landfill Energy recovery only |
End-of-life data source: COREPLA 2024 + Recyclass classification
Conservative scenario
The study also includes a conservative scenario simulating inefficiencies in the collection system (41.5% recycling, 41.5% incineration, 17% landfill). Even in this scenario, mono-material solutions maintain significant environmental advantages.
Methodological note: Cheese packaging
Important: For the cheese application, the mono-material PPHB/PP performs better on the Climate Change category (-11% CO2eq) but shows higher values on certain other impact categories (ozone depletion, fossil resource use and minerals/metals, water use). The overall advantage should be evaluated based on specific environmental priorities, considering that end-of-life recyclability remains a significant benefit from a PPWR perspective.
Peer-Reviewed Publication
The study has been published after international peer review in Environmental Impact Assessment Review (Elsevier), an academic reference journal for environmental impact assessment.
DOI: 10.1016/j.eiar.2025.108321 | Link: https://doi.org/10.1016/j.eiar.2025.108321
Research Team
| CIPACK – University of Parma | Poplast Group – R&D |
|---|---|
| Prof. Eng. Giuseppe Vignali Full Professor Department of Engineering and Architecture, University of Parma |
Eng. Gian Marco Ricci R&D and Quality Assurance Manager |
| Eng. Roberta Stefanini Researcher at the Department of Engineering and Architecture, University of Parma |
Frequently Asked Questions (FAQ)
What is an LCA study and why is it important for packaging?
Life Cycle Assessment (LCA) is a standardised methodology (ISO 14040/14044) that quantifies the environmental impacts of a product throughout its entire life cycle: from raw material extraction to disposal. For packaging, LCA enables objective comparison of different solutions and identifies which has the lowest overall environmental impact.
What is the difference between mono-material and multi-layer packaging?
Mono-material packaging consists of a single polymer (e.g. polypropylene PP or polyethylene PE), while multi-layer combines different materials (e.g. PET + aluminium + PE). Mono-material is recyclable in existing separate collection streams, while multi-layer generally is not and is destined for incineration.
Does mono-material packaging guarantee the same shelf life as traditional?
Yes. The Poplast mono-material solutions analysed in the study guarantee identical shelf life to traditional structures: 24 months for coffee, 12 months for dried fruit, 90 days at 4°C for cheese. Barrier properties are achieved through alternative technologies to aluminium (metallisation, coating, EVOH-free).
What does Recyclass Class B mean?
Recyclass is the European reference standard for plastic packaging recyclability certification. Class B indicates that the packaging is recyclable and can feed a closed-loop system, meaning the recycled material can be reused to produce new packaging. Classes E and F indicate non-recyclable materials, destined only for energy recovery.
How does this study relate to the PPWR regulation?
The European PPWR regulation (Packaging and Packaging Waste Regulation) introduces stringent recyclability requirements for packaging, to be defined through dedicated delegated acts. Poplast’s mono-material solutions are classified as Recyclass Class B, meeting the potential requirements to be established by the PPWR. Traditional multi-layer structures with aluminium or EVOH barriers will not comply with the new regulations.
Why was the study published in a peer-reviewed journal?
Publication in Environmental Impact Assessment Review (Elsevier) is verified by independent scientific reviewers; this lends credibility and transparency to the study, distinguishing it from non-validated LCA analyses or those commissioned without external review.
Request a Consultation
Would you like to evaluate the transition to mono-material solutions for your applications? Our R&D team is available to provide:
- Analysis of your current packaging structures
- Proposal of mono-material alternatives with equivalent shelf life
- Estimate of environmental benefits for your specific application
- PPWR compliance support