The One-Million-Tonne Gap: How the Packaging Industry Can Close the PCR Shortfall

One million tonnes – that’s the size of the post-consumer recycled materials (PCR) gap that, according to a new Interzero study, will emerge by 2030. For the authors of the report, one thing is clear: the requirements of the EU Packaging and Packaging Waste Regulation (PPWR) for recycled content will be difficult to meet without rapid change. In the Packaging People podcast, host Jan Malte Andresen talks with experts Patrick Neumann, Director of Product Management at Interzero, and Jonathan Scheck, Master of Packaging Development Management. They explain why the industry is under pressure – and which solutions are already realistic today. 

Patrick Neumann gets straight to the point: “The industry is at a crossroads.” Just a few years ago, he says, the mood was still euphoric – “plastics were scarce, demand was high.” Today, things look different: demand has collapsed, while the requirements of the EU Packaging and Packaging Waste Regulation (PPWR) are increasing. From 2030 onwards, fixed recycled-content quotas will apply to all packaging in the EU. But the reality is: high-quality PCR is scarce, expensive and technically demanding. “We have to search twice as long and pay twice as much to get food-grade PCR,” says Neumann. Jonathan Scheck adds: “The material we have today is suitable for pipes or paint buckets – but not for food packaging.” 

Why is PCR in such short supply? The experts cite several reasons: 

• Lack of investment in recycling infrastructure: without demand, no new facilities are built – and without facilities, no high-quality recyclates. 
   

• Technical hurdles: recyclates are more difficult to process than virgin material. Machines need to be adapted and processes optimized. 
   

• Cost factor: virgin material has been inexpensive and consistently available for years. For many manufacturers, switching to PCR is economically unattractive. 

 “It’s a classic chicken-and-egg problem,” says Scheck. “Quality is lacking because the infrastructure is. And the infrastructure is lacking because there is no demand.” 

The Interzero study “Circular Packaging 2030 – Strategies against the PCR shortage” not only highlights risks but also offers solutions. Neumann and Scheck name several immediate measures that companies should take now, including:  

Design for Recycling 

“What goes in at the beginning determines what comes out at the end,” Scheck explains. Packaging must be designed to support recycling processes – no unnecessary composite materials, no barriers that hinder sorting. 

Multi-track PCR Sourcing 

Secure volumes early – and don’t rely on a single partner. “The market is fragmented,” says Neumann. “Anyone with multiple sources is better protected.” 

Strategic Partnerships and Pilot Projects 

“It only works together,” Neumann emphasizes. Manufacturers, recyclers and brands need to collaborate to develop solutions and gain experience. 

“Many believe we still have time,” says Neumann. “But if everyone only starts in 2029, it will become a race of elephants for the last available volumes.” Those who act now secure not only material but also market advantages. There are already examples: brands that committed early to high recycled-content quotas approached the PPWR with confidence – and are also benefiting from a reputational boost.