Sustainability and Common Mistakes with Shrink Film

Why sustainability matters for shrink film

Shrink film is lightweight and efficient, but like all plastic packaging it raises questions about waste, recycling, and environmental impact. Making informed choices about film type, design, and process reduces footprint while preserving performance.

Sustainable material options

• Recyclable polyolefin: Many polyolefin films (like certain polyethylene and polypropylene blends) are compatible with existing recycling streams, especially when separated from other materials and kept clean.
• Mono-material designs: Packages made of a single polymer type are easier to recycle than mixed-material laminates. For example, choosing polyolefin film rather than a multi-layer laminate improves recyclability.
• Post-consumer recycled (PCR) content: Some shrink films include PCR content, reducing virgin plastic demand. Verify performance trade-offs and regulatory compliance for food contact if applicable.
• Compostable options: Emerging compostable films exist, but require industrial composting and carry limitations for mechanical heat shrinking or food contact. Always verify certification.

Design strategies to reduce material use

• Right-sizing: Select film width and sleeve size matched to the product to avoid unnecessary overlap and trimming waste.
• Optimize thickness: Use the minimum thickness that still protects the product and survives logistics. Over-thick film increases material use and cost.
• Bundling efficiencies: Design multipacks that balance stability with minimal film, e.g., perforations for easy retail separation or trays to reduce film need.

End-of-life considerations

Communicate recyclability clearly on packaging and avoid adhesives, inks, or labels that contaminate recycling streams. Work with material suppliers to provide data on resin codes and compatibility with local recycling infrastructure.

Common operational mistakes and how to avoid them

• Choosing the wrong film for the application: Mistake: Selecting a film with insufficient puncture resistance or wrong shrink temperature. Fix: Match film mechanical properties and shrink profile to the product and process.
• Overheating film or product: Mistake: Using excessive heat leads to brittle film, holes, or damaged product and can generate noxious fumes. Fix: Start with recommended temperatures, test, and use even airflow in tunnels.
• Poor film size selection: Mistake: Using oversized film wastes material and causes uneven shrink. Fix: Measure product dimensions, factor in sealing margins, and choose a film size close to final package dimensions.
• Ignoring film supplier specifications: Mistake: Running film without consulting shrink rates, temperature ranges, and recommended equipment settings. Fix: Keep technical data sheets on hand and conduct controlled trials.
• Not tracking packaging defects: Mistake: Failing to log and analyze packaging faults leads to recurring waste. Fix: Implement simple quality checks and track defect types to identify root causes.

Best practices for balancing performance and sustainability

• Run trials with PCR and mono-material films: Validate mechanical and aesthetic performance before full adoption.
• Standardize film sizes and thicknesses: Consolidating SKUs simplifies purchasing, reduces inventory, and allows buying in bulk—lowering cost and waste.
• Implement lean packaging reviews: Regularly audit packaging for opportunities to remove excess material while maintaining protection.
• Partner with recyclers and suppliers: Work with local recyclers to confirm what they accept and with suppliers to source more recyclable or lower-carbon films.

Regulatory and safety considerations

Food-contact applications require films with appropriate approvals. Also ensure that process ventilation meets workplace safety rules; some films can emit volatile byproducts if overheated. Always follow supplier safety data sheets (SDS).

Simple example of improvement

A specialty food brand switched from a multi-layer PVC-based sleeve to a mono-material polyolefin sleeve containing 30% PCR. After a short validation period, they achieved similar shelf appeal, improved recyclability claims, and reduced per-package carbon footprint.

What beginners can do today

• Ask suppliers for resin identification, PCR content, and recycling guidance.
• Run small-scale tests when changing film type to confirm packaging integrity and shrink behavior.
• Document process settings and defect rates before and after material changes to measure real impact.

Final thought



Sustainability in shrink film packaging is a combination of smarter material choices, design optimization, and disciplined operational practice. Avoiding common mistakes like wrong film selection or overheating not only improves package quality but also reduces waste, cost, and environmental impact—an outcome everyone benefits from.