European consumers actively separate Bag-in-Box packaging

Consumers across several European markets are already separating the different components of Bag-in-Box packaging before disposal, according to new research from Smurfit Westrock Bag-in-Box.

The study, conducted in Belgium, France, Germany and Sweden, examined whether users remove the flexible plastic bag from the outer cardboard box after use so that each component can enter the appropriate recycling stream.

Separation rates reach as high as 97%

The research found that the majority of consumers across all four markets already separate the two main components before disposal, with rates reaching as high as 97% in some countries.

The results suggest that consumers are willing to participate in more circular packaging systems when the required actions are straightforward and the structure of the pack makes material separation relatively intuitive.

Material separation influences recyclability

Bag-in-Box typically combines a corrugated or paperboard outer container with a flexible plastic bag and dispensing components. Each material can follow a different recycling route, making separation an important part of the pack’s end-of-life performance.

If the bag remains inside the cardboard box, the complete package may be assessed through the recycling stream of the dominant material. Separating the components allows the fibre and plastic elements to be managed independently.

PPWR raises expectations for separable packaging

The findings come as the European packaging industry prepares for increasingly demanding recyclability requirements under the Packaging and Packaging Waste Regulation.

The regulation places greater emphasis on designing packaging that can be effectively collected, sorted and recycled at scale. For multimaterial formats, the ease with which consumers can separate individual components can therefore become an important design consideration.

Country differences highlight role of local systems

Smurfit Westrock also identified differences in consumer behaviour between the four countries included in the study.

These variations reflect differences in waste collection infrastructure, national recycling guidance, consumer education and local disposal policies. A packaging format may therefore achieve different real-world recycling outcomes depending on the system in which it is placed.

Clear instructions can further improve results

The company argues that packaging design must be supported by clear communication explaining how each component should be handled after use.

Simple on-pack recycling instructions can help reduce uncertainty and encourage consumers to complete the separation step rather than placing the entire package into a single waste stream.

EasySplit aims to simplify consumer action

Smurfit Westrock has already developed its EasySplit Bag-in-Box format around this challenge. The design incorporates a pre-cut tear line intended to make separation between the plastic bag and cardboard box faster and more intuitive.

According to the company, correctly separating the two components can increase the overall recyclability of the packaging to more than 90%, compared with a substantially lower rate when the complete structure enters the paper recycling stream together.

Consumer behaviour becomes part of circular design

The research demonstrates that technical recyclability alone does not determine whether packaging materials return successfully to the recycling system. Consumer behaviour, disposal instructions and local infrastructure can have an equally important influence.

For packaging manufacturers, this means circular design increasingly needs to consider what consumers are realistically willing and able to do after the product has been used.

Study supports design-for-separation strategies

High separation rates across the four markets provide encouraging evidence for packaging formats designed around easily detachable components.

As Europe moves towards stricter recyclability requirements, the study suggests that combining intuitive structural design with clear recycling guidance could help multimaterial packaging achieve stronger real-world recovery performance rather than relying solely on theoretical recyclability calculations.