As interpack 2026 approaches, beverage packaging is emerging as a clear focal point, with material reduction, recyclability and system efficiency converging under growing regulatory and market pressure.
Across formats – from PET and glass to cans and cartons – suppliers are rethinking packaging design to meet sustainability targets while maintaining performance on high-speed production lines.
Lightweighting moves centre stage
Weight reduction is a defining trend. KHS, for example, is advancing its “premium lightweight” approach with a 0.25L mineral water bottle made from 100 per cent recycled PET, weighing just 6.2g.
The development reflects a broader shift – less material, but no compromise on functionality or line efficiency. Lightweight formats are increasingly being engineered alongside filling and blowing systems to ensure stability at industrial speeds.
At the same time, barrier technologies are evolving. KHS’ Plasmax coating – a silicon oxide layer under 100 nanometres thick – enables PET bottles to protect oxygen-sensitive beverages while remaining fully recyclable. The coating is removed during recycling without contaminating the material stream.
Design for recycling gains ground
Beyond primary packaging, attention is turning to components such as labels and adhesives – areas often overlooked but critical to recyclability.
CCL Label’s EcoFloat shrink sleeves, based on low-density polyolefin, enable clean separation in PET recycling streams, while WashOff labels support reuse systems by detaching cleanly during washing processes.
Henkel is also addressing this space with a mineral oil-free hot-melt adhesive, designed for high-speed labelling while achieving removal rates of up to 98 per cent during recycling.
Residue is separated from the material flow together with the remains of the labels. The hot-melt adhesive solution is compatible for both paper and plastic labels and ensures smooth operation at high speeds of up to 40,000 bottles per hour while maintaining low processing temperatures of 110 to 140°C. This protects equipment, saves energy and increases operational reliability.
These developments point to a more holistic approach – where every element of the pack is engineered for circularity.
Rethinking labels altogether
Some suppliers are going further, eliminating labels entirely.
Krones’ DecoBeam technology uses laser marking to apply product and branding information directly onto PET bottles, reducing material use and simplifying recycling. The system supports both white and black marking through CO₂ and fibre laser options.
For glass, its INKpression system transfers pre-printed designs directly onto containers, bypassing conventional labelling processes.
Cans continue to gain share
Aluminium cans remain on a growth trajectory, particularly among younger consumers. In Europe, recycling rates have exceeded 76 per cent, with deposit return schemes pushing rates as high as 90 per cent in some markets.
Producers are responding. Coca-Cola Europacific Partners Germany is investing in additional canning capacity, citing double-digit growth in canned beverage sales.
The format’s combination of recyclability, portability and branding flexibility continues to drive uptake.
Cartons under renewed scrutiny
Drinks cartons present a more complex picture. While lightweight and largely fibre-based, their multi-material construction continues to attract debate.
Industry data suggests established recycling pathways are in place, with tens of thousands of tonnes of materials recovered annually in Germany. However, recycling targets are still being missed, highlighting ongoing system challenges.
Regulation meets consumer reality
Regulatory measures are also shaping design outcomes. Tethered caps, now mandatory in parts of Europe, aim to reduce litter and improve recycling capture.
However, consumer feedback is mixed, with studies showing many users find them inconvenient in practice.
This tension between compliance and usability is likely to remain a key theme.
