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Which Thermoform Material is the Sustainable Champion?
Sustainability isn’t just a trend—it’s a movement shaping the future of packaging. With businesses and consumers demanding eco-friendly solutions, choosing the right material is more important than ever. Two leading contenders in the world of sustainable thermoforms are polylactic acid (PLA) and polyethylene terephthalate (PET). But which one truly delivers on sustainability? Let’s dive into the data and uncover the facts!
A Fair Contest: How We Compared PLA and PET
To ensure an apples-to-apples comparison, we used the EcoImpact-COMPASS Life Cycle Assessment (LCA) platform to analyze both materials under standardized conditions:
- Equal part weight of 24.8 grams for both materials.
- Transportation impacts excluded to focus purely on material sustainability.
Life Cycle Assessment (LCA) Results: Breaking Down the Environmental Impact
LCA provides a full picture of a material’s footprint, from production to disposal. Here’s how PLA and PET stack up:
Carbon Footprint
- PLA emits 38% more CO₂ than virgin PET.
- 100% post-consumer recycled (PCR) PET slashes carbon emissions by 65% compared to PLA.
Fossil Fuel Usage
Virgin PET requires more fossil fuels than PLA.
Recycled PET significantly reduces this disadvantage, making it a greener choice.
Water Consumption
- PLA’s water usage is a major concern.
- PLA production requires 2.9x more water than virgin PET.
- When compared to 100% PCR PET, PLA’s water demand jumps to 12.5x higher!
Takeaway: PET, especially when recycled, outperforms PLA in reducing carbon emissions and conserving water.
End-of-Life Realities: Compostability vs. Recyclability
Sustainability doesn’t end when packaging is disposed of. How a material breaks down—or gets reused—is just as crucial.
PLA: The Compostability Dilemma
- PLA is designed for industrial composting and can fully biodegrade under specific conditions.
- But here’s the catch: Industrial composting facilities are scarce, limiting PLA’s real-world composting potential.
- If PLA ends up in a landfill, it can decompose anaerobically, producing methane, a potent greenhouse gas.
PET: The Circular Economy Winner
- PET is one of the most widely recycled plastics, with a well-established global recycling system.
- Recycled PET (rPET) can be repurposed into new products, minimizing waste and extending its lifecycle.
- Because PET can be recycled multiple times, it supports a true circular economy, reducing reliance on virgin plastics.
Final Verdict: The Best Choice for Sustainable Packaging?
Choosing between PLA and PET isn’t black and white—it depends on your sustainability goals.
PLA: A bio-based option that reduces fossil fuel reliance, but its composting limitations and water-intensive production raise concerns.
PET: With lower carbon emissions, efficient water usage, and an established recycling system, PET—especially recycled PET—is the clear sustainability leader.
For businesses aiming to minimize their environmental impact, rPET stands out as the smarter, more sustainable choice. Want to make the best decision for your packaging? Focus on the balance between material sourcing, end-of-life management, and available recycling infrastructure.
Sustainable packaging isn’t just about the material—it’s about the full lifecycle impact. Let’s innovate responsibly and push the packaging industry toward a truly circular future. For more information please visit Plastic Ingenuity Circularity Services or Contact Us for a personalized Sustainability Assessment.
