DEEP DIVE | Plastic reduction

A ROADMAP TO USE LESS

A 5-step approach to cut plastic and meet sustainability targets

CHALLENGE

Closing critical gaps in plastic reduction

The client set bold PCR targets but was significantly behind, achieving ~7% vs. a 20% goal. This case study focuses on the first key action: Cutting plastic through new formats and consumption models, alongside efforts to improve recycling infrastructure and PCR sourcing in the supply chain.

STEP 1

IDENTIFY HIGH-PLASTIC DEPARTMENTS

and select SKUs with difficult-to-mitigate plastics and scalable learnings for broader application.

Various types of plastic packaging including bottles, clamshell containers, and cups, with some filled with almonds, set against a light background.

STEP 2

SELECT ALTERNATIVE PACKAGING

formats to cut plastic through innovative design. Rethinking packaging proved how cross-category inspiration and breakthrough materials reduce plastic. Circular options, like refillables, challenge habits but are essential for cutting waste and building sustainable routines.

Refills that deliver more. Refill systems cut costs by 50% and reduce CO₂ and plastic by 60–70%

Comparison of disinfecting wipes packaging, showing three different types with emphasis on refill, wet wipes, and plastic saving, including a graphic highlighting cost savings and eco-friendly features.

Breaking free from plastics. Fiber-based carton with separable films cuts plastic use by 80-90% and halves emissions versus HDPE containers

Packaging and recycling instructions for a box of disinfecting wipes, emphasizing 80% less plastic use with a fiber-based carton, reusable film lid, and plastic liner, and showing steps for recycling the package.

STEP 3

TEAR DOWN SELECTED PACKAGING SKUs

and competitor formats using LCAs to benchmark performance and establish a clear baseline for trade-offs and redesign potential. Track unit cost, CO₂ emissions, and plastic reduction to assess impact.

Chart comparing different yogurt packaging types with illustrations, images, and text describing properties such as material, headspace, weight, volume, and carbon dioxide emission. Types include baseline all plastic, cardboard-plastic combination, and coated paperboard, along with document images for visual identification.

STEP 4

ESTABLISH METRICS TO RANK PACKAGING FORMATS

by evaluating teardown outputs and assessing feasibility across cost, sustainability, scalability, and consumer acceptance. Leverage industry resources, vendor networks, and cross-functional partnerships to develop and align ranking criteria for informed decision-making.

A table showing a framework for assessing packaging trade-offs, including categories of Cost, Sustainability, Feasibility/Scalability, and Consumer Acceptance, with metrics, descriptions, and measures using green, yellow, and red indicators.

STEP 5

USE SCORECARD TO DRIVE PACKAGING TRANSITIONS

A structured scorecard helps teams evaluate packaging changes by weighing trade-offs, prioritizing key levers, and aligning with a single set of metrics to meet commitments. It balances short-term viability with long-term impact, enabling quick wins while laying the groundwork for future progress.

Comparison chart of five different packaging materials: baseline Polystyrene, Polypropylene + Paper, Coated Paperboard, Glass, and rPET across categories including cost, sustainability, feasibility, and consumer acceptance. The chart uses colors and symbols to indicate advantages, disadvantages, and current status for each attribute.

In 2023, I led a five-week sustainability sprint to accelerate plastic reduction in private brand packaging, collaborating across operations, supply chain, and merchandising to drive strategic insights and scalable solutions.