How to Embed Plastic Recycling Hierarchies into Medical Tray Design

Healthcare generates millions of tons of packaging waste each year, much of it from single-use sterile barrier systems and rigid medical trays. In fact, U.S. hospitals produce more than 5.9 million tons of waste annually, with 20–30% of that volume attributed to packaging .

While these packages are essential for product integrity and patient safety, they too often end up in landfills because of limited recyclability.

To make meaningful progress, medical packaging engineers need a decision-making framework that balances performance with end-of-life outcomes. One useful tool is the Plastics Hierarchy of Fates — a framework that ranks where plastics typically end up after use, from landfill to circular reuse .

By applying this hierarchy to material selection and design, engineers can create packaging that not only performs in sterile settings, but also moves higher up the recycling value chain.

The Plastics Hierarchy of Fates

The hierarchy ranks plastics by their most common “fates” after disposal:

1. Reuse → the highest-value outcome

2. Closed-loop recycling → recycled into similar-grade applications

3. Down-cycling → recycled into lower-value products

4. Energy recovery → incineration for fuel

5. Landfill → lowest-value outcome

For medical packaging, reuse is rarely an option. That means recyclability is the most practical path toward circularity .

How This Applies to Medical Packaging Materials

When evaluating rigid tray materials, the hierarchy provides clear guidance:

• PETG: A trusted workhorse in medical packaging, known for clarity and sterilization compatibility . However, PETG recycling is limited compared to other resins, often leading to down-cycling or landfill.

• APET: Increasingly popular due to its compatibility with existing PET recycling streams (RIC #1) . Modified APET offers a recycle-ready, cost-efficient alternative to PETG when application requirements allow.

• XPP (Impact’s recyclable polypropylene solution): A mono-material polypropylene engineered to meet sterilization and performance needs while flowing into PP recycling streams. Polypropylene is one of the fastest-growing resins in recycling infrastructure, with investments in curbside and advanced recycling expanding across the U.S.

The closer materials align with established recycling infrastructure, the further up the hierarchy — and the better the long-term outcome.

Design Principles for Recycling-Ready Trays

Material choice is foundational, but recyclability also depends on design decisions. Engineers can push medical trays higher up the hierarchy by:

• Eliminating mixed structures: Multilayers with no recycling pathway ultimately become waste .

• Selecting resins with strong domestic recovery infrastructure: PET and PP are widely accepted and have viable end markets .

• Reducing inks, coatings, and adhesives: These can interfere with recycling processes .

• Designing for standardization: Trays that are consistent and uniform are easier to sort and process.

Each decision matters when it comes to creating packaging that meets performance requirements and survives the recycling system.

The Role of Suppliers & Partners

Suppliers are a critical piece of the solution. At Impact Plastics, our team:

• Offers PETG, APET, and XPP materials aligned with recyclability goals.

• Provides application-specific guidance to balance sterilization, clarity, and sustainability.

• Helps customers apply design-for-recyclability best practices using frameworks like the APR Design® Guide .

By collaborating early, OEMs and converters can avoid costly redesigns and ensure new packaging programs meet both performance and sustainability goals.

Conclusion: Designing With End-of-Life in Mind

Medical packaging can’t compromise on safety — but it also can’t ignore sustainability. The Plastics Hierarchy of Fates is a practical framework for evaluating material and design choices, ensuring trays move toward circular outcomes instead of landfill.

At Impact Plastics, we’re committed to helping the healthcare industry design rigid medical packaging that performs clinically and supports a circular economy.

Ready to explore recyclable solutions for your medical trays? Connect with our team to learn more.