Introduction

When manufacturers think about sustainability, they often think of solar panels, water recycling or energy-efficient machinery. These are important, but there is another area where change can be faster, cheaper and more visible to customers: packaging.

Packaging touches every product a manufacturer sells. It uses materials, energy and transport, and much of it becomes waste soon after the product is opened. It is also what customers see, hold and throw away, so packaging choices shape how they judge a brand’s environmental responsibility. In research by Ipsos for the Paper and Packaging Board, 67% of consumers said the packaging material influences their choice of product.

For Sri Lankan manufacturers, especially exporters, sustainable packaging is becoming a commercial necessity as well as an environmental one. New rules in key markets, such as the European Union’s Packaging and Packaging Waste Regulation, are raising the bar. This article explains practical steps manufacturers can take, and how Dsigngo Group helps design and produce more sustainable packaging.

Why packaging is a good place to start

• It is visible. Customers and buyers notice packaging changes immediately.
• It is measurable. Material weights, types and recyclability can be recorded and improved.
• It can save money. Using less material and lighter packaging often reduces costs and freight.
• It is increasingly regulated. Early action prepares businesses for new rules.
• It supports exports. Many international buyers have packaging targets and ask suppliers to help meet them.

The basic principles

Sustainable packaging usually follows a clear order of priorities:

1. Reduce. Use only as much packaging as the product truly needs.
2. Reuse. Where practical, design packaging that can be used again.
3. Recycle. Choose materials that can be recycled in the places where the packaging ends up.
4. Renew. Use recycled content and responsibly sourced renewable materials.

Throughout, the packaging must still protect the product. Damaged or spoiled products waste far more resources than their packaging ever could.

Practical step 1: Remove what is not needed

Look critically at each layer of packaging. Common opportunities include:

• Removing an outer carton around a product that already has strong primary packaging.
• Eliminating plastic windows that add little value.
• Reducing the number of different materials in one pack.
• Removing unnecessary inserts, leaflets or decorative elements, or moving instructions online through a QR code.
• Replacing individual plastic bags with fewer, better-designed shipping cartons.

Practical step 2: Right-size the packaging

Oversized packaging wastes material, increases transport costs and can make products look as if they contain less than expected. Right-sizing means designing packs that fit the product closely while still protecting it. It also means planning carton and pallet sizes so more products fit in each container, which reduces freight emissions and costs.

Practical step 3: Choose materials carefully

Each material has strengths and limitations:

• Paper and board. Widely recyclable and made from renewable materials. Responsibly sourced board, such as FSC-certified material, adds credibility. However, paper may need coatings for moisture or grease resistance, which can affect recyclability.
• Glass. Recyclable and premium-looking, but heavy, which increases transport emissions.
• Metal. Highly recyclable and protective, suitable for products needing long shelf life.
• Plastics. Lightweight and protective, but many flexible and multi-layer plastics are hard to recycle. Mono-material plastics, made from a single type of plastic, are generally easier to recycle than mixed layers.
• Compostable materials. Useful in some situations, but only beneficial where suitable composting systems exist. They should not be assumed to break down in ordinary conditions.

The right choice depends on the product, its shelf life, how it travels and where the packaging will end up.

Practical step 4: Design for recycling

Even recyclable materials can become hard to recycle because of design choices. To improve recyclability:

• Use a single material where possible, or materials that separate easily.
• Avoid unnecessary laminations, metallised films and heavy coatings.
• Choose inks, adhesives and labels that do not contaminate recycling.
• Make components easy for consumers to separate, such as a paper sleeve on a plastic tub.
• Provide clear disposal instructions where rules allow.

Practical step 5: Use recycled and responsible content

Using recycled paper, board or plastics reduces demand for new raw materials. For food-contact packaging, recycled materials must meet safety requirements, so specialist advice is needed. For outer cartons, shipping boxes and many non-food items, recycled content is often straightforward.

Practical step 6: Offer reusable alternatives

For carrier bags and some types of retail packaging, reusable alternatives can replace single-use items. Non-woven bags, cotton bags and jute bags are durable, can carry strong branding and can be used many times. Dsigngo Group’s activities include non-woven bag production, giving businesses a branded, reusable option for retail, promotions and events.

Reusable bags deliver environmental benefits only when they are used many times, so they should be well made and attractive enough for customers to keep. A thoughtfully designed bag also keeps working as advertising every time it is carried, which gives brands a lasting return on the investment.

Practical step 7: Reduce transport packaging

Transport packaging, such as shipping cartons, pallet wrap and fillers, is often overlooked. Improvements include:

• Stronger cartons that allow less pallet wrap.
• Reusable crates or pallets for regular deliveries between known locations.
• Paper-based void fill instead of plastic.
• Better pallet patterns that reduce wasted space.

Packaging, shelf life and food waste

For food products, the most sustainable packaging is often the one that prevents waste. When food spoils before it is eaten, all the resources used to grow, process, transport and package it are lost. Good packaging can extend shelf life, protect products in transit and let consumers use only what they need.

Practical ideas include:

• Resealable packs that keep products fresh after opening.
• Portion sizes that match how customers actually use the product.
• Barrier materials matched to the product’s real needs, not over-specified.
• Clear storage instructions and date marking.

Any change to packaging materials for food should be tested for shelf life before launch.

Printing choices that reduce impact

Printing decisions also affect sustainability:

• Ordering realistic print quantities reduces obsolete stock and waste.
• Digital printing suits short runs and test products, avoiding large print runs that may not be used.
• Simpler designs with fewer special finishes can reduce materials and improve recyclability.
• Good colour management reduces spoilage during press set-up.
• Combining several products on one print sheet reduces waste.

Our article on print quality standards explains how controlled printing processes reduce reprints and waste.

Helping customers dispose of packaging correctly

Even recyclable packaging only helps if customers dispose of it correctly. Brands can help by:

• Printing simple disposal guidance, where rules allow.
• Making components easy to separate.
• Explaining packaging changes on websites and social media.
• Supporting local collection or take-back schemes where they exist.

Sustainability beyond packaging

Packaging is a strong starting point, but buyers increasingly look at the wider factory too. Related improvements include:

• Energy: efficient lighting, equipment and buildings, and renewable energy where practical.
• Water: reducing use and treating wastewater properly.
• Waste: separating, recycling and reducing production waste.
• Materials: choosing responsibly sourced raw materials.
• People: safe working conditions and fair treatment.

Recording progress in each area makes it easier to answer buyer questionnaires and supports certifications such as ISO 14001.

Regulations: what manufacturers need to know

European Union

The EU Packaging and Packaging Waste Regulation (EU) 2025/40 entered into force in February 2025 and generally applies from 12 August 2026. Its requirements are being phased in over several years. Early obligations include conformity documentation for packaging and restrictions on certain substances, such as PFAS in food-contact packaging. Later stages are expected to introduce harmonised labelling, recyclability requirements and other measures. Exporters supplying packaged goods to the EU should work with their importers to understand which requirements apply to them.

Sri Lanka

Sri Lanka has introduced regulations restricting certain single-use plastic items, administered by the Central Environmental Authority. Manufacturers should check which items are banned or restricted and plan alternatives.

Other markets

The UAE and other markets have also introduced measures to reduce single-use plastics, particularly bags. Rules differ by emirate and country, so exporters should check requirements with importers.

Working with packaging suppliers

Packaging suppliers are essential partners in sustainability. They know which materials are available locally, what each costs and how materials perform on production lines. When working with suppliers:

• Share your goals, such as reducing plastic or increasing recycled content.
• Ask for material options, specifications and certificates.
• Request samples and test them on your actual products and equipment.
• Agree how material changes will be approved and documented.
• Review progress together regularly.

Suppliers who understand your goals can suggest improvements you may not have considered.

Making honest environmental claims

Customers and regulators are increasingly alert to “greenwashing”, meaning vague or misleading environmental claims. Good practice includes:

• Making specific claims, such as “carton made from 80% recycled board”, rather than vague claims such as “eco-friendly”.
• Being able to prove every claim with evidence.
• Explaining limitations honestly, for example that a material is recyclable only where facilities exist.
• Using recognised certification marks only when certified.
• Avoiding images or colours that suggest environmental benefits that are not real.

Honest claims build lasting trust. Misleading claims can damage a brand quickly and may break advertising and consumer protection rules.

Measuring progress

To improve packaging sustainability, measure it:

• Total packaging weight per product or per shipment.
• Share of packaging that is recyclable in target markets.
• Share of recycled content.
• Number of different materials used.
• Transport efficiency, such as products per pallet or container.
• Damage and spoilage rates, to make sure protection is not compromised.

These measures also help answer questions from buyers and prepare for regulatory reporting. A simple spreadsheet, updated whenever packaging specifications change, is often enough to start, and it can move into business software later as the range grows.

Working with export buyers

Many international retailers and brands have packaging targets, such as reducing plastic or increasing recycled content. Suppliers who can propose improvements, supported by data, become more valuable partners. Ask buyers about their packaging goals and offer options, such as lighter cartons, mono-material pouches or reduced plastic. Present each option with its expected impact on cost, protection and recyclability, so buyers can make informed decisions. Suppliers that bring practical, well-tested ideas often find that sustainability opens conversations about new products and larger orders, not just compliance.

A 90-day starting plan

Manufacturers do not need to change everything at once. A simple 90-day plan can deliver early results:

• Days 1 to 30: List every packaging item used, with materials, weights, suppliers and costs. Identify the three biggest opportunities, such as an unnecessary layer or an oversized carton.
• Days 31 to 60: Develop and test alternatives for those opportunities, including shelf-life and transport tests where needed. Check costs with suppliers.
• Days 61 to 90: Introduce the approved changes, update artwork and specifications, and start measuring results.

Each cycle builds knowledge and confidence for the next round of improvements.

Weighing costs and benefits

Sustainable packaging decisions involve trade-offs. A recycled board may cost slightly more but reduce virgin material use. A lighter pack may save freight but need a stronger shipping carton. A paper-based option may look better to customers but need a coating to protect the product.

A balanced assessment considers:

• Material and printing costs.
• Transport and storage costs.
• Product protection and shelf life.
• Customer perception and brand value.
• Regulatory requirements in each market.
• Buyer expectations and potential new business.

Often, the overall result is positive even when one cost rises, because savings and new opportunities appear elsewhere.

Lessons from the group’s own brands

Dsigngo Group manages its own brands, including Raiden Tea, Raiden Coffee, Udari Nuts & Spices and the clothing brand Duiker. Packaging decisions for tea, coffee, spices and clothing involve the same balance of protection, presentation, cost and sustainability that clients face.

How Dsigngo Group helps

Dsigngo Group supports more sustainable packaging through:

• Packaging audits that identify opportunities to reduce, right-size and simplify.
• Structural design and dielines that use less material.
• Material advice and sourcing for paper, board and recyclable options.
• Print design that reduces inks and coatings where possible.
• Reusable non-woven bags and branded alternatives to single-use bags.
• Honest, clear on-pack environmental messaging.
• Physical mock-ups and testing to make sure products remain protected.

An illustrative example

Here is an illustrative example. It does not describe a specific client.

A Sri Lankan tea exporter packs tea bags in individual plastic sachets, inside a printed carton, inside a plastic outer wrap, inside a shipping carton.

• Audit. The outer plastic wrap and individual sachets are identified as the biggest opportunities.
• Reduce. A redesigned carton with a better seal replaces the outer plastic wrap.
• Material. Individual sachets are replaced with paper-based envelopes for the domestic range, after shelf-life testing confirms freshness.
• Right-size. The carton is resized to fit more units per shipping case, cutting freight costs.
• Claims. The pack states clearly which components are recyclable.
• Measurement. Packaging weight per carton and units per container are tracked.

A sustainable packaging checklist

1. Has every packaging layer been questioned and justified?
2. Is the pack sized closely to the product?
3. Are materials recyclable where the packaging will end up?
4. Can the number of different materials be reduced?
5. Has recycled or responsibly sourced content been considered?
6. Is there a reusable alternative for bags or transport packaging?
7. Does the packaging still protect the product throughout its life?
8. Are environmental claims specific and provable?
9. Have regulations in each target market been checked?
10. Are improvements measured and recorded?

Frequently asked questions

Is sustainable packaging always more expensive?

Not always. Reducing material and right-sizing often lower costs. Some recyclable or recycled materials cost more, but savings elsewhere can offset this.

Are compostable materials the best choice?

Only where suitable composting systems exist and the product suits the material. In many places, recyclable materials are a more practical choice.

Do we need to change our packaging for the EU?

If you supply packaged goods to the EU, you should check how the Packaging and Packaging Waste Regulation affects your products, working with your importer.

Where should a small manufacturer start?

Start with the packaging you buy most of, and look for layers that can be removed or reduced. These changes often save money immediately and need little investment.

Can you produce reusable branded bags?

Yes. We design and produce branded non-woven bags and other reusable options for retail, promotions and events.

Conclusion

Packaging is one of the most practical places for manufacturers to begin their sustainability journey. Reducing material, right-sizing, choosing recyclable materials, offering reusable alternatives and making honest claims can lower costs, satisfy buyers and prepare businesses for new regulations.

Dsigngo Group helps Sri Lankan manufacturers design and produce packaging that protects products, presents brands well and uses resources responsibly.

Want to make your packaging more sustainable? Ask us for a packaging review.

Request a Packaging Review

Sources

• Ipsos for the Paper and Packaging Board, consumer survey on packaging materials, as reported by Packaging Gateway.
• European Union, Packaging and Packaging Waste Regulation (EU) 2025/40, and guidance on application dates (Circular Online, Gerlach, Suus).
• Central Environmental Authority of Sri Lanka, regulations on single-use plastics.

Check each requirement against the original source before publishing.