Sustainable Packaging

Sustainable packaging spans a range of formats and material approaches, including PCR (post-consumer recycled) resin, bio-resin, mono-material recyclable, paper, and refillable packaging systems. The right option depends on your sustainability goals, product compatibility, regulatory requirements, and brand positioning. Evergreen supplies sustainable packaging across personal care, home care, food and beverage, and cosmetic applications.

PCR (post-consumer recycled) packaging is made using plastic resin recovered and reprocessed from post-consumer waste — such as used bottles and containers — rather than virgin petroleum-derived plastic. It performs comparably to virgin resin in most applications but carries a lower environmental footprint and supports brands' recycled content commitments. Evergreen offers PCR resin options across most plastic packaging formats, with inclusion rates ranging from 30–100% depending on the component type and performance requirements.

Bio-resin and biodegradable packaging are not the same thing, and the distinction matters for sustainability claims. Bio-resin refers to the origin of the raw material — it is plant-derived rather than petroleum-based — but the resulting plastic may not break down any faster than conventional plastic in a landfill or natural environment. Biodegradable packaging, by contrast, is specifically designed to decompose under defined conditions, such as industrial composting.

Paper tube packaging is a cylindrical packaging format constructed primarily from paperboard or kraft paper, used as a sustainable alternative to plastic tubes and sticks in personal care and cosmetic applications. It is most commonly used for products like deodorants, lip balms, solid skincare, and cosmetic powders, where a mono-material or fiber-based structure supports recyclability goals. Paper tube formats can be decorated with high-definition printing and are well suited to brands targeting plastic-free or reduced-plastic packaging commitments.

Refillable packaging is designed to be reused multiple times, with a durable primary container intended for long-term use and a lower-cost refill unit that replaces the product. Brands are investing in refillable systems to reduce single-use plastic consumption, meet sustainability targets, and build deeper consumer loyalty through a repeat-purchase model. Evergreen designs refillable systems that balance durability, aesthetics, and supply chain practicality across personal care and home care applications.

Choosing the right sustainable packaging depends on your product's formula compatibility, target sustainability metric, regulatory environment, and cost considerations. PCR resin is often the most straightforward starting point for brands with existing plastic formats, while glass and metal are traditional materials that are inherently sustainable. Newer formats like refillable systems and bio-resin offer distinct advantages but typically carry a higher cost premium. Evergreen works with brands to evaluate these tradeoffs and identify the most practical path to their environmental goals.

Sustainable packaging is held to the same quality and performance standards as conventional formats — material substitution does not reduce the requirements for dimensional accuracy, functional performance, or regulatory compliance. PCR and bio-resin materials are evaluated for compatibility with the product formulation and FDA compliance, while refillable systems are tested for durability across multiple use cycles. Evergreen QC engineers are onsite at all productions globally, and every facility in our network is audited across 165 quality management metrics regardless of the material type being produced.