As the UK introduces new packaging recyclability requirements, manufacturers must consider more than material selection. Changes to packaging formats can also affect coding quality, traceability and production line efficiency.
The UK’s packaging industry is undergoing significant changes. With Extended Producer Responsibility (EPR) for packaging already in operation and updated recyclability assessment requirements approaching in 2027, manufacturers are reviewing how their packaging is designed, produced and managed.
For businesses in food and beverage, cosmetics, household products and other manufacturing sectors, switching to more recyclable materials can introduce new challenges on the production line.
One important consideration is industrial coding and marking. Batch numbers, expiry dates, barcodes and traceability information must remain clear, accurate and readable, regardless of the packaging material.
What is changing under UK packaging EPR in 2027?
The UK’s Extended Producer Responsibility (EPR) scheme places greater responsibility on obligated packaging producers for the management of packaging waste.
In July 2026, PackUK published its updated Recyclability Assessment Methodology (RAM) 2027, which provides the framework for assessing the recyclability of household packaging supplied during 2027.
Under the methodology, packaging receives a red, amber or green rating based on its recyclability. These assessments influence the modulation of packaging waste disposal fees.
Importantly, RAM 2027 applies to the 2027 reporting year. Manufacturers must continue using RAM version 1.1 for their 2026 assessments.
For packaging producers, these developments create an additional incentive to review materials, packaging components and recyclability performance.
However, changing packaging materials also raises an important operational question:
Will existing coding and marking systems deliver the same performance on the new packaging?
How recyclable packaging changes affect industrial coding
Packaging materials differ in surface properties, composition, colour, thickness and response to different marking technologies.
When manufacturers change packaging materials, even relatively small modifications can affect the quality and consistency of printed codes.
1. Code contrast and readability
Clear, readable codes are essential for product identification and traceability.
Changes in packaging colour, surface finish or material composition may affect the contrast achieved by laser or inkjet marking systems.
For example, switching to a different plastic film may require manufacturers to reassess their marking parameters to maintain consistent code quality.
2. Compatibility with coding technologies
Not every coding technology performs equally well on every substrate.
The most suitable solution depends on the packaging material, production environment, marking requirements and line speed.
Manufacturers should therefore evaluate coding compatibility before introducing new packaging materials into production.
3. Production line efficiency
Packaging changes can also affect the positioning, stability and handling of products during coding.
New formats may require adjustments to marking equipment, printhead positioning or production line integration.
Testing these changes before implementation helps minimise production disruption and maintain coding consistency.
Choosing the right coding technology for recyclable packaging
Several industrial coding technologies can support manufacturers working with changing packaging materials.
Laser marking
Laser marking enables direct coding without inks or ribbons.
Depending on the substrate and laser technology, it can provide permanent identification on materials such as certain plastics, paperboard, glass and metals.
However, the suitability of laser marking must be assessed for each packaging material. Not all substrates respond in the same way, and marking performance should be validated before implementation.
Thermal transfer overprinting (TTO)
TTO technology is widely used for variable-data printing on flexible packaging films.
It is particularly relevant for food manufacturers printing expiry dates, batch numbers and other product information on packaging films.
When switching to alternative or recyclable films, manufacturers should verify ribbon compatibility, print adhesion and code quality.
Continuous inkjet (CIJ)
CIJ technology offers flexible coding for high-speed production lines and a wide range of packaging applications.
It can be used to print variable information on bottles, containers and other packaging formats.
Ink selection and substrate compatibility remain important considerations when materials change.
Thermal inkjet (TIJ)
TIJ systems provide high-resolution printing for applications such as cartons, paperboard and other compatible packaging surfaces.
They can be particularly useful when manufacturers require clear text, barcodes and variable product information.
Why packaging traceability remains essential
Although packaging EPR focuses on environmental responsibility, product traceability remains a separate and essential requirement for manufacturers.
Changes in packaging design must not compromise the identification of products throughout manufacturing and distribution.
Reliable coding supports:
- Accurate batch and lot identification.
- Clear date marking.
- Product identification throughout the supply chain.
- Efficient product recalls when required.
- Consistent management of variable production data.
For manufacturers handling multiple packaging formats, integrating coding equipment with centralised data management systems can also help reduce manual errors.
Packaging recyclability and product traceability are different requirements, but both need to be considered when redesigning packaging operations.
Five checks before changing your packaging material
Before introducing a new packaging material, manufacturers should assess its impact on their existing coding process.
1. Check substrate compatibility
Confirm that the current coding technology is suitable for the new packaging material.
2. Test code readability
Evaluate contrast, print quality and barcode readability under realistic production conditions.
3. Review production line speed
Ensure that the coding system can maintain consistent performance at the required operating speed.
4. Verify variable data management
Check that batch numbers, dates and other variable information remain accurate across different packaging formats.
5. Validate the complete application
Test the coding process on actual packaging samples before implementing changes across the production line.
These checks can help manufacturers identify potential problems early and avoid unnecessary production disruption.
Preparing UK manufacturing lines for 2027
As packaging requirements evolve, manufacturers have an opportunity to review both packaging design and coding performance.
The introduction of RAM 2027 does not, in itself, require manufacturers to replace their coding equipment.
However, businesses planning changes to packaging materials should consider how these modifications could affect identification, readability and traceability.
At Macsa UK, we provide industrial coding and marking technologies designed to support manufacturers across different packaging materials, production environments and traceability requirements.
From laser marking and inkjet printing to flexible packaging coding and automated identification, our solutions help businesses maintain reliable coding performance as their production needs evolve.
