Plastic and corrugated packaging—two materials that are nearly impossible to avoid in our day-to-day lives. Both materials play major roles in our modern world, from unboxing your latest online purchase to the packaging that lines store shelves. However, as businesses and consumers grow more eco-conscious, the debate over which is the more sustainable choice is heating up. In this article, we compare the environmental footprint of each material and find a clear winner between the two.
The Battle of Materials: Corrugated vs. Plastic
On one side, you have corrugated packaging—primarily made from renewable resources and boasting high recyclability. On the other, plastic—a material that’s durable but notorious for its long-lasting environmental impact. The differences between these two start with the raw materials and extend all the way to end-of-life disposal. Here’s how they stack up:
Corrugated Packaging’s Environmental Impact
Renewable Materials
Corrugated packaging is a true sustainability success story, and it all starts with where the material comes from. Made primarily from wood pulp sourced from sustainably managed forests, corrugated materials are renewable by design. The industry has evolved to ensure that paper fibers are harvested responsibly. Tree planting and forest management practices outlined by the Sustainable Forestry Initiative and the Forest Stewardship Council® ensure that trees are replaced as they’re harvested. In other words, corrugated packaging supports a system where resources are replenished rather than depleted.
High Recyclability
High recyclability is another key characteristic of corrugated packaging. In the U.S., 93% of corrugated products are recovered and recycled into new materials, making it one of the most recycled packaging materials worldwide. This nearly closed-loop system means fewer resources are needed for new production, and less waste ends up in landfills.
Corrugated packaging is also biodegradable. Even if it’s not recycled, it decomposes within a few months. For companies focused on sustainability, having a strong end-of-life story like this is ideal.
Plastic Packaging’s Environmental Impact
Lightweight, Durable, and Low Cost
Plastic packaging has long been a go-to for industries thanks to its durability, lightweight nature, and low cost. However, beneath these advantages lies a significant environmental cost. The production of plastic is heavily reliant on fossil fuels, contributing not only to resource depletion but also to high levels of greenhouse gas emissions. The energy-intensive process of converting petroleum into plastic involves complex chemical reactions that release pollutants into the atmosphere, further exacerbating climate change.
Lower Recyclability
While plastic packaging is considered to be fairly recyclable, the recycling rate is low. Despite widespread efforts to build up recycling infrastructure (recycling centers and programs) and change the habits of consumers, only about 9% of plastic is actually recycled. The primary challenge is that plastic isn’t just one material but a category or many material types, each with its own recycling requirements. Contamination during the recycling process often leads to entire batches being discarded, and the infrastructure to sort and process these plastics is often limited. As a result, most plastic ends up in landfills (or rivers, lakes, and the ocean), where it takes hundreds of years to decompose.
Plastic is non-biodegradable and persists in the environment for generations, breaking down into smaller and smaller particles known as microplastics. These microplastics have been found everywhere—from the deepest parts of the ocean to the air we breathe. They pose a growing threat to wildlife and ecosystems, which includes our own well-being. While there have been some innovations in bioplastics and improved recycling techniques, the problem remains largely unsolved. When you factor in the long-term damage plastic inflicts on the environment, it’s clear that plastic’s short-term benefits come at a significant long-term cost.
| Corrugated Material | Plastic | |
| Resources | Renewable | Non-Renewable |
| Manufacturing Pollutants | Low | High |
| Recyclability | High 90% | Fair |
| Recycling Infrastructure | Well-established | Needs Improvement |
| Recycle Rate | High 90% | Low 9% |
| Circular Economy Impact | Support a circular economy (highly reused and recycled) | Limited support for a circular economy (reused and recycled significantly less) |
The Verdict: Why Corrugated Packaging Comes Out on Top
When it comes to sustainability, corrugated packaging is the clear winner. It’s not just about being recyclable—it’s about being part of a circular economy where materials are continually reused and repurposed. Unlike plastic, which can clog up ecosystems for generations, corrugated materials have a second life or can be recycled into new products time and time again. Plus, corrugated manufacturing companies like President Container Group are doubling down on eco-friendly practices by integrating things like solar energy and in-house recycling systems to further reduce environmental impact.
Need sustainable packaging for your product? Connect with one of our experts today and discover how corrugated packaging can meet your needs while minimizing environmental impact.