Reducing EPR Costs Through Smart Packaging Choices
As Extended Producer Responsibility (EPR) regulations continue to roll out across the UK, businesses face increasing scrutiny—not just on what they produce, but how it’s packaged. EPR shifts the financial responsibility for packaging waste from local authorities to producers, meaning packaging choices now directly impact your bottom line.
For businesses shipping products nationwide and beyond, optimising your packaging is one of the smartest ways to minimise both environmental impact and EPR costs. At Macfarlane Packaging, we work with customers every day to help them make informed, cost-effective packaging decisions.
In this blog we’ll give you some strategies on how you can reduce your EPR burden through smarter packaging choices.
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Understand how EPR costs are calculated
Before making changes, it’s essential to understand what affects your EPR charges. Under UK EPR legislation, fees are based on:
- The weight and material of packaging used.
- Recyclability and ease of sorting of the packaging components.
- Where your packaging is collected once it has been used.
For household packaging, the more complex and less recyclable your packaging is, the higher your fees will be. The UK Government have recently published their Recyclability Assessment Methodology (RAM), which will set the framework for businesses to assess their packaging. It mandates that businesses selling packaging that is likely to end up at a household need to report the recyclability of that packaging based on a RAG (Red, Amber, Green) rating system.
Materials that are hard to recycle at scale, like polystyrene, PVC and mixed-material packaging are expected to be rated red under the system and therefore will likely be subject to higher fees going forward, if they are being sent to UK households.
Using mono-material packaging, packaging made from a single material (like all-paper or all-Polyethylene) will help to simplify recycling and is more likely to be classified as recyclable.
So, with the new household packaging legislation framework in mind, how can you lower the impact to your business? Here are some suggestions:
Reduce packaging weight
EPR fees are weight-based, so lightweighting your packaging—without compromising protection—is an easy win.
- Use right-sized packaging to eliminate unnecessary material.
- Opt for lightweight alternatives like thinner corrugate grades that still offer high strength or lower micron plastic.
- Remove redundant layers of packaging where your product doesn’t require it.
- Switch to lighter weight options, for example replacing boxes with mailers for smaller profile products.
This also is a great way to reduce cost across products that may not fall into EPR – for example on stretch wrap.
Design for recycling
Designing packaging for easy sorting and recycling is key to lowering EPR-related costs. This includes:
- Avoiding black plastics, which are difficult to detect in recycling facilities.
- Clearly labelling packaging components to aid disposal by the end user.
- Minimising mixed materials—for instance, don’t glue plastic windows to cardboard or laminate paper with foil.
Smart packaging design can make a product easier to recycle and reduce the likelihood of incurring higher disposal fees under EPR schemes.
Rethink material choices
Switching to more recyclable materials can significantly reduce your EPR costs as the introduction of the Recyclability Assessment Methodology (RAM) and Red, Amber, Green rating system will classify packaging materials based on their recyclability.
However, you need to balance the weight of replacement and ease of recyclability with the weight of less recyclable alternatives.
For example, switching to paper instead of plastic will incur a lower EPR processing tonnage cost but, paper can be bulkier and heavier than plastic. This means that the weight of material you use will increase.
Improve data reporting with accurate audits
- Many businesses underestimate the importance of accurate packaging data. Under EPR, producers must submit detailed reports on packaging usage—by weight, material type, and recycling potential.
- Conduct a packaging audit to identify what materials you’re using, in what quantities, and how recyclable they are.
- Track supplier data and ensure packaging spec sheets include weight and composition breakdowns.
- Automate data collection where possible to streamline reporting and reduce errors.
Macfarlane’s Packaging e-trading tool helps our customers get clear visibility of their packaging usage, enabling more accurate reporting and informed decision-making.
Collaborate with packaging experts
If you’re unsure where to start, work with a packaging partner who understands both the commercial and environmental aspects of EPR compliance.
At Macfarlane Packaging, we combine data-driven insights with decades of experience to:
- Identify cost-saving opportunities in packaging design and material usage.
- Provide sustainable packaging solutions aligned with current regulations.
- Show you the full impact of packaging optimisation including cost, and sustainability improvements using our Packaging Optimiser.
- Help to future-proof your packaging strategy for upcoming changes in legislation.
EPR doesn’t have to be a burden. With the right packaging strategy, it’s an opportunity to cut waste, reduce costs and build stronger environmental credentials. Smart packaging choices today mean fewer fees and headaches tomorrow.
If you’re ready to review your packaging and see how you could reduce your EPR costs, get in touch with Macfarlane Packaging. Our experts are here to help you deliver sustainable, cost-effective packaging solutions—without compromising performance.