8 Tips to Navigate Life Cycle Assessments for Circular Packaging  

Much has been written about why life cycle assessments (LCAs) matter––their role in helping companies choose between different materials and packaging formats, their ability to measure the climate impact of business decisions, even their ability to help evaluate environmental risks of new solutions. 

But the reality is, LCAs can become complex very quickly. They usually involve a multitude of assumptions and data––from the origins of materials (cradle) to how they are transported through complicated supply chains, all the way to how they are disposed of (grave) or recovered via reuse or recycling.  

Yet if navigated thoughtfully, LCAs are packed with a wealth of information for creating data-backed packaging strategies that contribute to waste reduction goals and advance positive climate impacts.  

Here, we share 8 tips to help brands navigate the most critical aspects of any packaging emissions analysis: 

1. Focus on the biggest drivers of impact: New materials often account for the majority of emissions. Keeping packaging in circulation for longer––thus avoiding the need for new materials––is a key driver to reduce the climate impact of packaging. For reusable containers, the return rate, and the associated number of uses tied to it, is the most critical factor to drive down packaging emissions. When one LCA assumes that a reusable container is used on average 100 times (99% return rate) and another assumes 2 times (50% return rate), emission outcomes will vary widely. 
2. Put some weight behind the weight of your packaging: Lightweighting is generally the lowest hanging fruit opportunity for companies to reduce their packaging impact. But there’s only so much a product can be lightweighted before this impacts its performance and recyclability. Today, new lightweighting innovations enable durability while not compromising on high packaging quality, functionality and recyclability, opening more opportunities for reduced emissions. 
3. Account for all distances of transportation, including transport to landfill: In the U.S., virgin materials usually travel hundreds, if not thousands, of miles from production sites to their point of sale. Materials that end up in landfill also travel hundreds of miles from point of consumption to their grave (over 500 miles on average in the case of New York City), but distances traveled to landfill are often overlooked in LCA analyses.  
4. Give thought to the food waste that packaging may carry to landfills: Food waste in food packaging decays over time and, in the absence of oxygen, creates methane in landfills. Methane, a greenhouse gas, is 28 times more potent than CO2 in trapping atmospheric heat. Any packaging system, such as reusable or compostable options, that serve as a vehicle to properly dispose of (i.e., compost) food scraps, and keep them out of landfills, has significantly reduced emissions compared to current single-use packaging systems. 
5. Consider the difference between recycling and use of recycled content: The GHG Protocol has two methods for calculating recycling emissions. One method benefits packaging that uses recycled content; the other benefits products that are recycled at end-of-life. Since we need both things to be true to create a truly circular economy, focus on designing packaging that meets both criteria. For LCAs, consider using an average of both calculations. 
6. Don’t discount impact through incineration: The emissions impact of incineration is left out of many LCAs. In today’s carbon accounting protocols, incineration emissions (i.e., the energy produced from incineration) are accounted for in their next product, thus burning packaging after use does not add to the emissions of that piece of packaging. While this can seem to provide a discount towards packaging emissions, this is not a circular strategy as valuable packaging materials are lost instead of kept in circulation. 
7. Assess the implication of clean grids: Switching to clean energy is an immediate opportunity to reduce packaging emissions. However, when analyzing the impact of clean grids, remember to apply the benefits of lower manufacturing and transportation emissions to incumbent materials and processes as well.   
8. Remember that infrastructure assets do not impact emissions directly: Emissions associated with bins, machines and other capital infrastructure are not typically included in packaging LCAs, based on the GHG Protocol. Incumbent solutions like landfilling have infrastructure associated with them as well, and are not included in LCAs, so new infrastructure for future solutions should be held to the same standard as existing infrastructure.

LCAs are just one datapoint within the larger equation 

When implementing any packaging solution, emissions are just one part of the equation—packaging decisions affect our planet beyond their climate impact. Waste generated, water usage, biodiversity loss, social and human health risks are all critical aspects to be assessed for a responsible and sustainable circular packaging strategy. 

We hope these LCA tips help packaging designers and decision makers make more holistic analyses, leading to greener packaging innovation.

Get in touch with Closed Loop Partners’ Center for the Circular Economy at [email protected] to dive deeper into packaging emissions and to collaborate on designing, testing and scaling circular packaging solutions.  

Findings are based on the Center for the Circular Economy’s proprietary LCA model. A special thank you to our partners at Columbia University for their contributions to this work.