1. Reduce Material Usage Through Right-Sizing and Lightweighting

EPR fees are often calculated by weight, meaning that reducing packaging material can have a direct financial impact. Right-sizing minimizes excess space and reduces void fill, while lightweighting uses thinner, stronger materials to maintain durability with less mass.

How Group O helps:

• Conducts SMART Audit® to identify material reduction opportunities
• Sources high-performance films that are lighter yet stronger—often at cost-neutral or better rates
• Aligns material changes with EPR eco-modulation incentives

SMART Audit® Stretch Film Optimization Case Study - See the data: We proved you can remain cost neutral or lower costs will maintaining product protect with PCR. 

2. Choose Recyclable Materials with Post-Consumer Recycled Content (PCR)

Packaging that is widely recyclable and incorporates PCR content is often rewarded with lower EPR fees. Moving from multi-material to mono-material packaging improves recovery rates, while PCR use supports both compliance and corporate sustainability targets.

How Group O helps:

• Sources PCR films, and tapes, 100% recycled papers and cornerboard, reusable and recyclable airbags, and more that helps meet performance needs
• Performs Life Cycle Assessments (LCAs) to evaluate environmental and cost benefits - LCAs can help reduce EPR fees in Oregon currently. Make sure to check with the Circular Action Alliance (CAA) to stay on top of current state laws. 
• Recommends alternatives to problematic materials that hinder recycling

3. Improve Design for Recycling and Sorting Efficiency

Even recyclable materials can be penalized under EPR if design choices make them hard to process. Labels, adhesives, and inks can interfere with sorting equipment or contaminate recycling streams.

How Group O helps:

• Designs custom packaging with recyclability in mind
• Advises on label substrates and adhesives that won’t disrupt recycling
• Optimizes labeling & identification to maintain both function and recyclability

4. Eliminate Problematic or Non-Recyclable Components

Certain materials—like non-recyclable plastics, multi-layer composites, or black plastics—can trigger higher fees or outright bans in EPR programs. Eliminating these not only reduces costs but also future-proofs packaging.

How Group O helps:

• Audits existing packaging to flag high-risk materials
• Provides ongoing continuous improvement for our customers—bringing new ideas to the table, sharing the latest innovations, and re-auditing regularly to ensure your packaging remains compliant, cost-efficient, and high-performing
• Sources compostable, recyclable, or mono-material alternatives
• Manages supplier transitions for a smooth implementation

5. Track, Report, and Continuously Improve Packaging Performance

EPR is evolving rapidly, and eco-modulation rates can change yearly. Accurate tracking and reporting of packaging weight, recyclability, and PCR content is key to maintaining compliance and spotting cost-saving opportunities.

How Group O helps:

• Builds strong, long-term partnerships—learning your operations inside and out so we can proactively identify packaging improvements over time
• Provides clear packaging data to support your reporting requirements and identify opportunities for optimization
• Recommends trusted resources like the Circular Action Alliance (CAA) for the most current EPR guidance and compliance updates
• Continually brings new ideas, materials, and design strategies to help you reduce costs and improve sustainability year after year

Why Choose Group O for EPR Packaging Support

We combine packaging innovation with EPR expertise, helping clients:

• Lower fees through eco-modulated packaging design
• Maintain product protection and brand integrity
• Source sustainable materials at competitive prices
• Simplify compliance through data-driven reporting
 
Contact Group O today to schedule your SMART Audit® and discover how small changes in your packaging can make a big impact on your EPR fees.