PCPA Releases First U.S. Design Guide for Poly-Coated Paper Packaging
The Poly Coated Paper Alliance (PCPA) has released its 2026 Design for Mill Recyclability Guidance, the first comprehensive U.S. design guide focused on poly-coated paper packaging. The guidance covers packaging formats including milk and juice cartons, coffee cups, ice cream containers and other food and household packaging.
The new resource provides brands, converters and manufacturers with a common framework for designing poly-coated paper packaging with greater consideration for the requirements of U.S. paper mill end markets. It addresses a gap in existing design-for-recyclability guidance, which has traditionally focused on other packaging materials and formats.
The guidance is based on direct feedback from U.S. and Canadian paper mills representing more than 90% of consumption of relevant recovered fiber grades containing poly-coated paper packaging, including Grade 54 Mixed Paper, Grade 52 Cartons and other poly-coated white fibre grades.
PCPA developed the framework using four compatibility categories: fully compatible, conditionally compatible, not compatible and unknown. Existing international guidance, including work from the 4evergreen Alliance, was also considered and adapted to reflect conditions at North American mills.
Additional testing conducted by PCPA, including RFID tracking, optical sorting and bale audits, helped identify how packaging components perform throughout the recycling process. The findings highlight that relatively small design decisions can affect the compatibility of poly-coated paper packaging at paper mills.
The guidance examines factors including coatings, adhesives and other non-fiber components, along with updated considerations related to repulpability. By bringing mill feedback into the packaging design process, the initiative aims to give brands and converters greater visibility into how design choices can influence recycling outcomes.
The release comes as Circular Action Alliance (CAA) works toward implementation of extended producer responsibility (EPR) requirements in California. The new guidance could provide CAA with an industry-developed, mill-informed resource when considering recovery strategies and fees in California and other states where it operates.
PCPA emphasized that the guidance is not a mandatory standard and does not guarantee regulatory compliance. The alliance plans to update the resource as additional mill feedback, testing, standards and regulatory requirements emerge.
