Sustainable Tape as a Key Player in Cutting Packaging Waste

November 4, 2025|Adhesives/Sealants, Exclusive Features, Materials, Sustainable

Paper-based packaging tapes are designed to be easily recycled along with the cardboard boxes they’re used on,and been validated by Western Michigan University to be “curbside recyclable.” Image courtesy of Shurtape.

Converging Forces Create an Urgent Need for Innovative Solutions

By Bradley Dunlap, Director of Product Marketing – Industrial Packaging, Shurtape

As the packaging industry pursues ambitious sustainability goals, a longstanding challenge persists. Even carefully designed recyclable materials are being diverted to landfills because of small, non-recyclable components that contaminate the recycling stream. These seemingly minor elements can undermine significant sustainability investments and prevent otherwise recoverable materials from re-entering the supply chain.

While cardboard boxes and plastic containers receive great attention, one seemingly minor component has emerged as a critical factor in achieving true packaging sustainability: tape. Innovative solutions like sustainable tape are transforming this landscape. These breakthrough technologies represent a fundamental shift toward more responsible packaging processes while helping businesses meet increasingly stringent sustainability commitments.

The Packaging Waste Problem

The scale of packaging waste presents a mounting environmental and economic challenge that extends far beyond what consumers see in their recycling bins. The global plastic waste crisis has reached critical proportions: only 9 percent of all plastic waste is recycled, while 50 percent goes to landfills, 19 percent is incinerated and 22 percent becomes mismanaged litter. The United States Environmental Protection Agency estimated in 2019 that about 96 million tons of packaging material waste were generated each year in the U.S., with traditional packaging tapes contributing to recycling contamination.¹

Businesses face escalating waste disposal costs, while market research indicates consumer demand for sustainable packaging continues to intensify according to market research.^2,3 Studies reveal Gen Z and Millennials are increasingly choosing brands that align with their values, and consumers are highly critical of perceived packaging according to consumer research. Studies indicate transparent sustainability efforts can boost brand loyalty and trust, making packaging decisions a critical component of brand strategy.

Regulatory pressure adds another layer, as governments worldwide implement extended producer responsibility laws that hold manufacturers accountable for their packaging’s entire lifecycle.⁴

In the United States alone, California passed legislation in 2022 requiring a 25 percent reduction of plastics in single-use packaging and foodware by 2032. Oregon passed similar laws in 2021 targeting reduction of plastics and improvement in recycling for packaging, paper, and foodware. New York has proposed legislation for 2025 calling for a 30 percent reduction in plastics in packaging materials over 12 years.⁵ These emerging EPR laws are driving packaging redesign to meet stricter sustainability standards, with proactive brands reducing risk, avoiding fees and staying ahead of regulation.

These converging forces have created an urgent need for innovative solutions that address both environmental impact and operational efficiency.

Tapes made with Post-Consumer Recycled (PCR) materials significantly reduce the use of virgin plastic, and are often sourced from recycled PET bottles. Image courtesy of Shurtape.

Current Industry Response

Consumer packaged goods companies are actively rethinking their packaging strategies to cut waste and boost sustainability. According to PMMI Media Group, current sustainability strategies include adopting more recyclable packaging materials, reducing the amount of packaging used, reducing packaging waste in operations and incorporating more recycled content.⁶ These efforts reflect a comprehensive approach to addressing packaging’s environmental footprint across the entire supply chain.

Sustainable Tape: A Material Innovation

Leading manufacturers have introduced two distinct approaches to sustainable tape solutions to help businesses meet their environmental goals: recyclable paper-based tapes and tapes made from recycled content materials.

Paper-Based Recyclable Tapes: Paper-based packaging tapes are designed to be easily recycled along with the cardboard boxes they’re used on. These tapes have been validated by Western Michigan University to be “curbside recyclable.” This means they can be left on the box and don’t need to be removed by the end consumer before recycling, which simplifies the process and helps ensure more cartons get recycled. These solutions offer excellent quick stick and holding power, and are available in both automated and manual options with drop-in ready compatibility for existing packaging operations.

Post-Consumer Recycled Content Tapes: Another approach involves tapes made with Post-Consumer Recycled (PCR) materials, often sourced from recycled PET bottles. These tapes are made from 90 percent PCR rPET film, delivering significant virgin plastic reduction while maintaining proven performance similar to traditional biaxially oriented polypropylene (BOPP) tape. Purpose-built for use in automation and drop-in ready for existing operations, these tapes offer uncompromised strength and performance, making them a sustainable, high-performing alternative to traditional plastic tapes.

The environmental impact of sustainable tape is substantial according to our Renewable Resource Quotient (RRQ), a method to assess the amount of natural, renewable and recycled content in a product. For example, a company using 10 pallets of tape, converting from virgin BOPP to 90 percent rPET packaging tape results in an 8,211-pound reduction in virgin plastic consumed, saves 25.82 barrels of oil in fossil fuel use, and reduces water consumption by 951,380 gallons. By using recycled content, these products help drive a circular plastics economy and significantly reduce virgin plastic use in carton sealing operations.⁷

Advanced Sustainable Packaging Systems

One critical aspect of waste reduction involves rightsized tape application, ensuring every inch of tape used on each roll is utilized efficiently, with full utilization of the tape’s adhesive. Pairing packaging tape with application methods that minimize waste and rework can deliver significant results. For a 10-pallet user, rightsized tape systems can reduce tape production by 1,131 pounds of film consumed, decrease the number of pallets purchased by 1.4, reduce tape on boxes by 5 percent through tab rightsizing and eliminate 8 percent of wasted tape by eliminating stub rolls.

These systems and their accompanying tape solutions are engineered to be drop-in ready, allowing for seamless integration into existing packaging operations without requiring extensive modifications or downtime. This means organizations can begin experiencing sustainability achievements upon installation, making it an ideal solution for companies seeking immediate environmental improvements. The combination of proven environmental benefits and effortless implementation positions these systems as solutions that deliver both environmental responsibility and operational convenience.

Real-world implementation case studies show rapid adoption, with users reporting improved operational efficiency alongside environmental benefits.⁸

Industry Impact and Adoption

This individual success has translated into broader industry momentum, driving market transformation. Adoption of sustainable tape solutions has accelerated in recent years, with major retailers and manufacturers incorporating sustainable tape requirements into their supplier specifications. Companies, including major e-commerce and retail leaders, have implemented sustainability scorecards that factor packaging recyclability into vendor selection processes according to a report by imark.⁹ This trend extends beyond retail, with manufacturing sectors including automotive, electronics and consumer goods integrating recyclable packaging tapes into their operations.

The benefits extend well beyond waste reduction, encompassing improved brand reputation, regulatory compliance and supply chain resilience. However, challenges remain in achieving widespread adoption, particularly around education and awareness. Many packaging decision-makers lack familiarity with sustainable tape options and their performance characteristics, leading to hesitation in switching from established solutions according to a report by McKinsey & Company.¹⁰ Using sustainable tape helps a company’s wider sustainability efforts. This tape works with other circular economy initiatives, making the overall environmental impact even bigger and easier to measure according to Tomra Systems ASA.¹¹

Looking Ahead: The Future of Sustainable Packaging Materials

Emerging innovations in sustainable tape technology promise even greater environmental benefits and expanded applications. Research and development efforts focus on compostable backing materials and smart packaging integration that could revolutionize how tape functions within packaging systems. Regulatory trends strongly support continued growth in sustainable packaging materials, with proposed legislation in multiple jurisdictions targeting packaging recyclability standards and extended producer responsibility requirements.

Market growth projections indicate significant expansion in the sustainable packaging tape segment, driven by regulatory compliance requirements and corporate sustainability commitments according to Markets and Market Reports.¹² This growth creates opportunities for businesses to gain competitive advantages through early adoption while contributing to broader environmental goals. The transformation requires collaborative action from packaging engineers, sustainability managers, procurement teams and senior leadership to prioritize solutions that balance performance, cost and environmental impact.

Sustainable packaging solutions demonstrate that environmental responsibility and superior performance can coexist. As the packaging industry continues to evolve toward circular economy principles, recyclable tape will play an increasingly vital role in achieving truly sustainable packaging systems that benefit businesses, consumers and the environment alike.

About the Author

Bradley Dunlap is the Director of Product Marketing – Industrial Packaging at Shurtape. For additional information visit: https://shurtapetech.com/about/sustainability/ and these online resources:

Sustainable Packaging Solutions:

https://www.shurtape.com/packaging/products/sustainable/recycled-series/

Reducing Tape Waste:
https://shurtapetech.com/sustainability/how-we-are-reducing-tape-waste-with-shurseal/

Rightsized Tape Application:

https://www.shurtape.com/packaging/shurseal/