The Four Packaging Decisions That Impact EPR Fees

Extended Producer Responsibility (EPR) programs are spreading, and they're changing how packaging gets priced. Under these programs, the fees a producer pays are shaped directly by packaging design- which means the choices packaging teams make today increasingly determine what they'll owe tomorrow. The good news is that most programs reward the same basic packaging improvements, so a few well-chosen design moves can lower exposure across the board, often without a full redesign. At Sealstrip, we're tracking these programs closely and building solutions specifically to help our customers stay ahead of them.

How the Fees Work

Most EPR programs are built around a base fee that's adjusted up or down- a mechanism called eco-modulation. Lighter, recyclable, mono-material, and simpler designs tend to earn lower fees. Heavier, multilayer, mixed-material, and hard-to-sort formats tend to cost more. For most packaging in most of these states, one organization, the Circular Action Alliance (CAA), handles registration, reporting, and fees, which makes it a practical first stop for confirming what applies where you sell. In most cases, four packaging decisions drive most of that difference. *

Use Less Material Weight is one of the biggest levers. Because fees are largely a function of material type and weight, using less material is the most direct way to lower what you owe- and some programs are now moving beyond incentives to require outright reductions in both material weight and component count. Reduction should reach every element, not just the primary structure: labels, liners, tear strips, seals, and film layers all add up. Small savings, multiplied across millions of units, become significant.
Design for Recyclability Recyclability is the next major driver. Packages that move cleanly through existing recycling streams earn lower fees; those that combine polymer families or are hard to sort are penalized. That's why so many teams are shifting toward mono-material and recycle-ready structures- designs that satisfy recyclability goals and cut fee exposure at the same time. Industry groups like the Sustainable Packaging Coalition (SPC), a project of the nonprofit GreenBlue, publish practical guidance for designing recycle-ready packaging and communicating recyclability clearly, which makes those goals easier to hit and to prove. The Association of Plastic Recyclers (APR) also provides widely used design guidance and testing protocols that help companies evaluate whether a package is compatible with existing recycling systems.
Consolidate and Reduce Components Every added part carries a cost: more material, more complexity, and more to sort at end of life. Multi-part and multilayer designs sit consistently among the higher-fee categories. The opportunity isn't simply to review components; it's to determine where they can be eliminated or combined. Can several functions- easy-open, resealable, tamper-evident- be delivered through fewer parts, or built into the package itself, without sacrificing performance? This is exactly the kind of consolidation Sealstrip's approach is designed to enable: building easy-open and resealable convenience into the film itself, which can replace a separate zipper, use less material, and/or keep the package to a single recyclable mono-material.
Use PCR Strategically Post-consumer recycled (PCR) content earns lower fees and counts toward compliance, so it belongs in the toolkit. But it's a supporting move, not a substitute. PCR doesn't offset high material use or a poorly structured, hard-to-recycle package. Reducing weight and designing for recyclability come first; PCR is most effective when it's part of a package that's already designed with reduction and recyclability in mind.

Before You Redesign Everything

As EPR expands, many brands feel pressure to overhaul their packaging all at once (or, in some cases, simply feeling like "deer in the headlights"). In practice, the smartest first step is usually a focused look at the material, recyclability, and components already in play- where meaningful savings and some of the easiest wins are often hiding. Sealstrip is paying attention to how these programs evolve and acting on it, with solutions built to reduce weight, minimize components, enable recyclability, and support mono-material designs- all while delivering the resealable performance that protects products, keeps them fresh, and satisfies consumers. As the rules keep changing, our goal stays the same: helping our customers lower EPR exposure and succeed.

*Please note: this information is simplified for easy reading - the links throughout, and the resources below, are included for referencing the specifics.

Helpful Resources

Association of Plastic Recyclers (APR) — design guidance, recyclability criteria, and testing protocols used throughout the packaging industry to help evaluate compatibility with existing recycling systems.

Circular Action Alliance — the producer responsibility organization administering most state EPR programs, including registration, reporting, and fee details.

SPC's Extended Producer Responsibility guide — a plain-language reference on how EPR programs and fees work, from the Sustainable Packaging Coalition (a project of GreenBlue).

Sealstrip — lightweighting, component reduction, and mono-material, recycle-ready reseal solutions.