Plastics : Creating Easy-Remove Labels for Plastic Recycling

Why label removability matters:

When plastic containers enter recycling facilities, labels that remain attached can cause several problems

• Adhesives and non-compatible label materials can contaminate the recycled plastic
• Labels may interfere with optical sorting equipment
• Label residue can reduce the quality and value of recycled plastic
• Creating easily removable labels helps address these challenges while making recycling more efficient.

Key design approaches for removable labels:

1. Water-soluble adhesives:

• These adhesives dissolve in water during the washing phase of recycling.
• Example: A beverage company switched to a water-soluble acrylic adhesive that maintains adhesion during product use but dissolves in the hot water wash phase of recycling.
• Best for: Food and beverage containers that will encounter wet conditions during recycling processing.

2. Heat-release adhesives:

• These adhesives lose their tackiness when exposed to heat during recycling.
• Example: A personal care product manufacturer uses labels with heat-release adhesives that separate cleanly during the hot wash cycle in recycling facilities.
• Best for: Plastic containers going through hot wash recycling processes.

3. Pressure-sensitive removable adhesives:

• These provide temporary bonding that allows consumers to peel labels away easily.
• Example: A specialty food producer uses a low-tack adhesive that allows consumers to cleanly peel away labels before recycling.
• Best for: Products where consumer pre-removal of labels is desired or expected.

4. Mechanical design solutions:

• Physical design features that facilitate easy removal.
• Examples: pull tabs at the corner of labels, perforated labels that tear away easily, sleeve labels with perforation lines for easy removal
• Best for: Larger containers or where adhesives may be problematic.

Material considerations:

Compatible label materials:

• Same polymer as container: using a label made from the same plastic as the container (e.g., HDPE label on HDPE bottle)
• Floating, sinking principles: choose materials that will separate naturally in recycling float tanks:
• For PET bottles (#1): Use labels with density lower than 1.0 g/cm³ (like PE or PP) that will float while PET sinks
• For HDPE/LDPE bottles (#2, #4): use labels with density higher than 1.0 g/cm³ that will sink while the plastic floats

HDPE (High-Density Polyethylene): strong, durable plastic with good chemical resistance. Used for milk jugs, detergent bottles, and toys. Recycling code #2.
LDPE (Low-Density Polyethylene): flexible, lightweight plastic that's easy to form. Used for plastic bags, squeeze bottles, and food wrap. Recycling code #4.
PET (Polyethylene Terephthalate): clear, strong plastic with good gas barrier properties. Used for water bottles, food containers, and polyester clothing. Recycling code #1.

Ink considerations:

• Non-bleeding inks: use inks that won't bleed into wash water
• Minimal coverage: reduce ink coverage when possible
• EuPIA-compliant inks: use inks that meet European Printing Ink Association standards

Practical implementation examples:

Example 1 - beverage bottle solution -

PET water bottles needed recyclable labels that wouldn't contaminate the PET recycling stream.

Solution implemented:

• Thin BOPP (biaxially oriented polypropylene) labels
• Water-soluble adhesive
• Designed to float in water separation tanks
• Minimal ink coverage
• Small easy-grip tab at corner

BOPP (Biaxially Oriented Polypropylene): thin, strong plastic film stretched in both length and width directions during manufacturing. This orientation process increases strength, clarity, and moisture resistance. Commonly used for packaging labels, tape, and food wrappers due to its excellent printability and durability.

Result: 

Labels cleanly separated during recycling without contaminating recycled PET.

Example 2 - household cleaner bottle -

HDPE detergent bottles with hard-to-remove labels were causing recycling contamination.

Solution implemented:

• Switched to wash-off adhesive
• Added "Remove Label" instruction with a visible pull tab
• Used label material with density higher than 1.0 g/cm³ to ensure separation from floating HDPE
• Designed labels with perforations for easy tearing

Floating HDPE: High-Density Polyethylene with a density less than 1.0 g/cm³ that naturally floats in water. This property is utilized in recycling facilities where separation tanks sort plastics. HDPE floats while denser plastics sink, enabling efficient material sorting and recovery.

Result: 

Recycling centers reported cleaner HDPE recycling stream and fewer contamination issues.

Example 3 - food container sleeve label -

Full-body shrink sleeve labels were preventing proper identification and recycling of containers.

Full-Body shrink sleeve labels: plastic film labels that completely wrap around containers, covering the entire surface. They're made from heat-shrinkable materials that conform tightly to container shapes when heated. While offering 360° branding and tamper evidence, they can interfere with recycling by preventing proper identification of the underlying container material.

Solution implemented:

• Added perforation lines to facilitate removal
• Printed clear instructions for consumers to "Remove sleeve before recycling"
• Used floatable material for PET containers
• Minimized ink coverage

Result:

Increased recycling rates as containers could be properly identified and processed.

Testing your label design:

Test your removable label design for:

• Functionality during use: Ensures label stays attached during normal product lifecycle
• Removal ease: Test how easily labels detach in simulated recycling conditions
• Recycling compatibility: Verify that any adhesive residue doesn't impact recycling
• Consumer understanding: Check if consumers understand removal instructions

Communication best practices:

To enhances label removal rates use:

• Simple instructions: "Peel before recycling" or "Remove label"
• Visual cues: Arrows showing pull direction or dotted lines indicating where to tear
• Clear contrast: Ensure instructions are visible (not hidden by design elements)
• Multiple languages: Consider your market and include appropriate languages

By combining these design approaches with clear consumer communication, brands can significantly improve the recyclability of their plastic packaging while maintaining attractive product presentation.