Is plastic-free packaging always the most sustainable choice? At first glance, the answer might seem like a resounding yes. But the reality, as Heather Nixon – sustainability, NPD, and regulatory manager at Bio-D – has discovered over nearly a decade of research, is far more nuanced. In the race to reduce environmental impact, Bio-D’s journey reveals a deeper story of trade-offs, lifecycle analysis, and practical decisions that go beyond buzzwords.

Challenges with the pouch revolution

Pouches are often perceived as an eco-friendly alternative to rigid packaging. They use less plastic per unit and are lighter, which helps reduce transport emissions. However, their actual environmental performance is more complicated. According to Bio-D's research, most pouches are made from 100% virgin plastic and often incorporate multiple plastic layers, making them virtually non-recyclable. Additionally, many pouches are manufactured in Asia, resulting in high carbon emissions from transport. Consumer behavior is another concern: a University of York study revealed that 64% of consumers dispose of pouches in general waste, further undermining their sustainability claims.

Even refill schemes come with their own set of problems. Some companies bypass proper relaundering processes, introducing contamination risks. While some pouches come with non-return valves to avoid this, they then become non-refillable – negating a key circularity principle.

Is glass greener?

Glass packaging is often touted as a premium and sustainable solution. However, Bio-D found it lacking in several areas. Glass is energy-intensive to produce and recycle, and its weight (up to 12 times heavier than plastic) significantly increases transport emissions. While recyclable, the environmental cost of glass production and logistics often outweighs its benefits for everyday consumer products like cleaning agents.

Why PCR plastic made sense for Bio-D

After comprehensive testing and lifecycle evaluation, Bio-D chose post-consumer recycled (PCR) plastic as its go-to material. The benefits were clear: reduced CO₂ emissions, lower transport-related environmental impact, and the ability to divert plastic waste from landfills. Currently, 100% of Bio-D’s bottles are made from PCR plastic, and 50% of their caps incorporate it as well. These measures have already led to the saving of nearly 60 tonnes of CO₂e annually.

Designing for efficiency

Another aspect often overlooked in the sustainability conversation is product design. Bio-D’s Dishwasher Tablets, for instance, are smaller than standard alternatives, requiring less packaging and transport space. This smart, compact design contributes to a lower overall environmental footprint, showing how innovation in product formulation complements packaging efforts.

Ongoing improvements and the road ahead

Despite these strides, Bio-D acknowledges its work isn’t done. Increasing the PCR content in caps remains a challenge due to strength and durability concerns. However, the company is committed to further testing and collaboration with suppliers to overcome these obstacles.

“Sustainability isn’t a finish line; it’s an ongoing responsibility,” Nixon emphasizes. This ethos underscores the need for constant innovation, transparent practices, and holistic thinking in packaging design.

The role of regulation and collaboration

Nixon believes future progress hinges on more than just voluntary initiatives. She calls for clearer government guidance, stricter regulations on recyclability and greenwashing, and better alignment between waste systems, manufacturers, and policymakers. She also advocates for stronger investments in refill infrastructure and closed-loop logistics, which will be essential for enabling meaningful circularity.

Final advice for businesses

For companies exploring sustainable packaging, Nixon’s advice is clear: do your homework. Collaborate with universities, engage with your supply chain, and look beyond your sector. Real solutions often require unconventional thinking and rigorous testing. Trends alone don’t make packaging sustainable—science, practicality, and context do.

Bio-D’s journey offers a candid, research-driven perspective on sustainability. It shows that true progress requires resisting simplistic answers and being open to complex, sometimes surprising conclusions about what’s best for the planet.