Poly Coated Paper Alliance Releases U.S. Design Guidance for Mill Recyclability

The Poly Coated Paper Alliance (PCPA) has released its 2026 Design for Mill Recyclability Guidance, described as the first comprehensive U.S.-specific design guide for poly-coated paper packaging, covering products such as milk and juice cartons, coffee cups, ice cream containers, and other food and household packaging.

The guidance provides brands, converters and manufacturers with a framework for designing poly-coated paper packaging with greater consideration of how materials are processed by paper mills. It comes as Circular Action Alliance (CAA) prepares to implement extended producer responsibility (EPR) requirements in California, where the guide could serve as a resource for recovery strategies and fee development.

PCPA said the guidance addresses a gap in U.S. packaging design resources by identifying packaging features and components that can affect recyclability at paper mills. Its recommendations are based on direct input from U.S. and Canadian mills representing more than 90% of consumption of relevant recovered fiber grades containing poly-coated paper packaging, including Grade 54 Mixed Paper and Grade 52 Cartons.

The guide classifies packaging components into four compatibility categories: fully compatible, conditionally compatible, not compatible and unknown. PCPA said the framework draws on existing international guidance, including work by the 4evergreen Alliance, but was adapted to U.S. mill conditions based on feedback from participating mills.

Additional testing conducted by PCPA, including RFID tracking, optical sorting and bale audits, was also used to inform the guidance. Mill feedback identified differences in how coatings, adhesives and other non-fiber components affect processing, including considerations related to repulpability.

Jason Pelz, vice president of Recycling at the Carton Council, said the guidance incorporates paper mill operating conditions into the packaging design process and is intended to help the industry identify where current packaging designs are compatible with recycling systems and where further work is needed.

The release also comes as EPR programs expand in the U.S. Scott Byrne, vice president of Global Sustainability & Industry Affairs at Sonoco, said the framework could provide producers with a reference as EPR implementation develops in California and other states.

PCPA emphasized that the guidance is not a mandatory standard and does not guarantee regulatory compliance. The alliance plans to update the resource as additional mill feedback, testing, standards and regulatory requirements become available.

Source: The Poly Coated Paper Alliance (PCPA)

SUNSHINE Spotlight: PCPA’s new U.S. design guidance uses paper mill feedback and testing to identify how coatings, adhesives and other packaging components can affect the recyclability of poly-coated paper products.