The Impact of Packaging Design on Recycling Efficiency in Municipal Systems

The rapid growth of consumer packaging has placed significant pressure on municipal solid waste management and recycling systems worldwide. While recycling technologies and policies have advanced, recycling efficiency remains constrained by upstream factors, particularly packaging design choices made during product development. This study investigates the impact of packaging design characteristics such as material composition, color, labeling, size, and structural complexity on recycling efficiency within municipal recycling systems. Using a systems-engineering perspective, the research analyzes how design decisions influence material recovery rates, contamination levels, sorting accuracy, and operational costs in material recovery facilities (MRFs). A mixed-method approach combining secondary data analysis, process mapping, and efficiency metrics is employed to evaluate recycling outcomes associated with different packaging configurations. The findings demonstrate that design-for-recyclability principles significantly improve sorting accuracy, reduce contamination, and enhance overall recycling throughput. The study highlights the importance of integrating packaging design optimization into municipal recycling strategies and offers actionable recommendations for manufacturers, policymakers, and waste management operators to improve recycling performance and environmental sustainability.