Durability and Functionality of Conventional Polymeric Packaging Materials in Reusable Packaging Systems

Abstract Reusable packaging is increasingly recognised as a sustainable solution to address issues related to increasing packaging waste generation and harmful environmental impacts. The packaging sector consumes a significant portion of Europe’s plastic production, which is mostly single-use packaging. There is a sense of urgency to develop sustainable reusable alternatives. Unlike single-use packaging, the longevity of reusable plastic packaging is paramount, necessitating material durability and functionality. This study examines the durability of conventional polymeric packaging materials (polyethylene terephthalate (PET), polypropylene, high-density polyethylene) and investigates the effectiveness of scratch resistance additives. A specialised test set-up was created to evaluate the performance of various polymers in reusable takeaway food packaging scenarios. The research included scratch testing, wear analysis and wash cycles to assess the reuse potential of these materials. Qualitative measures were employed to compare material characteristics. Results indicated that polymer type significantly affects hardness and scratch performance, while additives had minimal impact on hardness and modulus. Although current scratch resistance additives do not effectively mitigate wear in reusable packaging in the experimental scenarios, tailored additives could present potential in increasing the durability and longevity of reusable packaging. PET demonstrated notable recovery post-washing, suggesting that washing conditions could influence material resilience. This study emphasises the need for further research to optimise scratch resistance additives and understand the impact of washing conditions on different polymers, aiming to enhance the design and longevity of reusable packaging systems.