Hint: You can do both!

This article is part of Group O’s EPR & Tertiary Packaging series, exploring how data-driven packaging optimization reduces cost, material use, and regulatory risk.

Extended Producer Responsibility (EPR) is reshaping how companies evaluate packaging decisions. In our opening article, EPR and Tertiary Packaging: Why Tracking Matters More Than Ever, we outlined how EPR fee structures reward reduced material usage, lower virgin plastic content, and strong reporting. This article builds on that foundation by addressing one of the most common questions companies face: what happens when stretch film is still the best solution?

Stretch film is often the first material companies look to cut. But removing film entirely isn’t always feasible—or responsible—when load stability, safety, and product protection are on the line. The smarter approach isn’t elimination. It’s optimization.

Why 30% PCR Stretch Film Changes the Conversation

Modern 30% post-consumer recycled (PCR) stretch film delivers equal—or greater—performance compared to traditional virgin films. When paired with line optimization and testing, PCR film often enables down-gauging, reducing the total amount of film used per load.

This approach delivers multiple EPR advantages at once:

 • Reduced virgin plastic content
 • Lower total material placed into the system
 • Improved recyclability and reporting outcomes
 • Importantly, these benefits are achieved without sacrificing load containment.

Proven Results at Scale

In a recent study across 11 high-volume manufacturing sites, Group O evaluated 30% PCR stretch film under real-world operating conditions:

 • 10 of 11 sites achieved cost savings
 • Savings reached up to 18 percent
 • 56,000 pounds of stretch film eliminated annually
 • Approximately 20 percent reduction in CO₂ impact
 • No up-gauging required to maintain performance

The takeaway is clear: sustainability improvements don’t have to come at the expense of operational performance—or cost. Dive deeper into this PCR stretch film case study to see how savings were achieved at scale. Looking for more evidence? Review another stretch film sustainability case study with proven results.

One Manufacturer. One Line. Measurable Impact.

Those results aren’t limited to large multi-site studies. They show up just as clearly at the individual facility level.

A leading manufacturer of high-performance adhesives was wrapping thousands of pallets each year using a conventional 65-gauge stretch film. While the process ensured load stability, it came with higher material usage, rising costs, and increasing pressure to align with sustainability goals and upcoming EPR requirements.

Through Group O’s SMART Audit®, the team tested a high-performance 49-gauge stretch film with 30% PCR content against the existing 65-gauge film. Key performance metrics—including force-to-load, stretch efficiency, pallet coverage, and cost per pallet—were evaluated under real operating conditions.

The results demonstrated that the PCR film not only matched performance but exceeded it in critical areas, allowing the manufacturer to downgauge without compromising load integrity.

The outcome:

 • 24% reduction in total film usage through downgauging
 • 47% reduction in virgin plastic introduced into the packaging stream
 • Approximately 5% annual cost savings
 • Improved force-to-load and secure shipments
 • Direct support for sustainability commitments and EPR compliance

By switching to a 49-gauge, 30% PCR stretch film, the manufacturer reduced material waste by nearly a quarter, lowered packaging costs, and took measurable steps toward circularity—without changing their wrapping process or increasing risk in transit.

Why This Matters Under EPR

EPR does not penalize companies for protecting their products. It penalizes inefficiency. PCR stretch film directly addresses EPR criteria by reducing virgin resin use while maintaining—and often improving—material efficiency.

When film is the right answer, using better film is how companies stay compliant, competitive, and prepared.

Continue the EPR Series

This article focuses on optimizing stretch film through PCR content and data-backed testing. In the rest of the series, we explore additional tertiary packaging opportunities:

 • Cornerboard Optimization – Reducing paper use with equal or greater strength
 • Tape Under EPR – rPET and kraft alternatives to traditional BOPP tape
 • Reusable Airbags & Dunnage – Turning single-use packaging into a reusable asset

Each of these upcoming articles reinforces one principle: measuring packaging performance beats guessing every time. Check back soon for the next article in our EPR Series on tertiary packaging optimization. To learn more reach out to our packaging team today.