FMCG Packaging and EPR: A Sustainable Match Made on Earth?

Packaging plays a critical role in the fast-moving consumer goods (FMCG) sector — protecting products, communicating brand identity, and driving convenience for consumers. 

The sector produces vast quantities of packaging materials, often using plastic composites and single-use formats that contribute significantly to global waste. According to Our World in Data, packaging accounts for over 40% of the planet’s plastic waste, most of which comes directly from FMCG products.

This challenge is driving monumental shifts in legislation, innovation, and consumer expectations, and businesses that fail to evolve risk both reputational and financial consequences.

The Consumer Perspective: Demand for Accountability

Consumers are increasingly aware of the environmental cost of convenience. Research from Greenpeace South Asia revealed that 93% of consumers expect FMCG brands to take accountability for the plastic waste they create. In the UK, this is reflected in the growing demand for transparency, recyclability, and circularity in packaging.

Eco-conscious shoppers are not only avoiding brands that fail to act — they’re actively rewarding those that do. For FMCG companies, this isn’t just about ethics — it’s about commercial survival in a competitive, values-driven marketplace.

UK Legislation: The Packaging Landscape Is Changing

To curb packaging waste and shift responsibility back to producers, the UK government has introduced a series of new laws targeting packaging across all sectors, with particular relevance to FMCG. These include:

1. Extended Producer Responsibility (EPR)

EPR legislation requires producers to cover the full net cost of collecting, recycling, or disposing of their packaging. This includes not only the packaging used to wrap products, but also transit packaging like boxes, pallets, and wrapping films.

Key elements:

• Mandatory packaging reporting (in place from 2023 for large producers; SMEs to follow)

• Modulated fees beginning in 2025 — packaging that is difficult to recycle will incur higher costs

• Labelling requirements — consistent “Recycle” or “Do Not Recycle” symbols to help consumers dispose correctly

2. Plastic Packaging Tax (PPT)

Introduced in April 2022, the PPT imposes a tax of £200/tonne on plastic packaging that contains less than 30% recycled plastic. FMCG products wrapped in plastic film, pots, tubs, and trays are directly impacted.

3. Deposit Return Scheme (DRS)

Planned for rollout in England, Wales, and Northern Ireland in 2025, the deposit return scheme will place a deposit on drinks containers to encourage consumer recycling and reduce litter. FMCG drinks brands will need to align with the scheme.

How This Impacts FMCG Packaging

The result of these legislative changes is a new packaging economy, one where recyclability, material choice, and design simplicity directly influence a company’s costs and compliance burden.

FMCG brands using complex, multi-material packaging will face steeper EPR fees and brand risks. On the other hand, those adopting mono-material, fully recyclable solutions can reduce costs, enhance consumer trust, and gain a competitive edge.

How Greyhound Box Supports the FMCG Sector

At Greyhound Box, we specialise in designing and manufacturing corrugated cardboard packaging solutions that meet the unique needs of FMCG brands. With decades of experience and in-house manufacturing capabilities, we provide a strategic edge to FMCG producers seeking compliance, cost-efficiency, and sustainability.

What sets Greyhound Box apart is our deep understanding of the operational requirements of the FMCG industry. Packaging must not only look good, but also perform under pressure — whether it’s in freezers, supermarket shelves, or in complex supply chains. Our packaging is designed for strength, stackability, efficient transit, and compliance with evolving sustainability standards.

Our team works closely with FMCG brands to:

• Undergo a Packaging Review to optimise packaging for recyclability and compliance

• Recommend the right board grades and finishes based on product requirements

• Create branded, high-performance packaging that meets both visual and functional standards

• Reduce over-packaging and streamline materials to lower environmental and financial costs
• Develop product-specific solutions that are optimised for transit 

For FMCG brands, working with Greyhound Box means access to a full-service packaging partner that understands the pace, scale, and pressures of the industry and has the tools to support businesses through change.

Helping MJ Petfoods and Proteins Improve FMCG Packaging

In 2023, Greyhound Box partnered with MJ Petfoods and Proteins, the manufacturer behind the Dougie’s brand of raw frozen dog food. As an FMCG product with strict temperature and hygiene requirements, Dougie’s packaging needed to be robust, freezer-friendly, and sustainable.

MJ Petfoods’ Managing Director, Mark Robinson, approached us with a challenge: redevelop their existing freezer packaging to improve its recyclability without compromising strength or storage performance. With around 11,000 boxes leaving our factory floor every month, this was a high-volume, mission-critical packaging solution.

We engineered a bespoke corrugated cardboard box made from a board grade capable of withstanding cold storage and the rigours of transportation. Importantly, the box eliminated the need for non-recyclable shrink films typically used in freezer packaging. Our chosen board was composed of at least 80% recycled content and fully recyclable — aligning perfectly with MJ Petfoods’ sustainability goals.

Beyond functionality, we incorporated Dougie’s brand identity into the box design. From logo placement to social media callouts, we printed everything using water-based, non-toxic inks that deliver a strong visual impact without harming the environment. 

“We couldn’t be more chuffed with the freezer boxes that Dougie’s raw petfood products now call ‘home’! We asked Greyhound Box for a versatile design that improved the efficiency of our packing process, and they delivered on every front. Our petfood is now stored and transported in fully recyclable Dougie’s branded boxes that are attractive to the eye. Not to mention a resilient design to give us a bonus feeling of confidence.” Mark Robinson, Managing Director of MJ Petfoods and Proteins

Today, Greyhound Box produces thousands of these branded, eco-conscious boxes each month, ensuring Dougie’s products reach stores in pristine condition while meeting the highest sustainability standards. This project highlights how FMCG packaging can — and should — deliver on both performance and environmental responsibility.

The Future of FMCG Packaging

For FMCG companies, packaging is no longer just a protective shell, it is a business-critical component tied to brand reputation, compliance, and environmental performance. As the regulatory landscape becomes more stringent, packaging innovation will be essential for companies to maintain competitiveness and customer loyalty.

Greyhound Box continues to lead the way in providing practical, scalable, and sustainable packaging solutions to UK FMCG businesses. Whether you’re preparing for EPR, or simply looking to reduce your carbon footprint, we can help turn your packaging into a strategic advantage.

Interested in transforming your FMCG packaging? Contact us today to explore a solution tailored to your product.