Circular packaging is becoming one of the most important strategies for brands that want to reduce waste, improve resource efficiency, and move toward a more responsible production model.
As sustainability expectations grow across industries, packaging is no longer seen only as a protective element. It is now a key part of product design, brand value, and environmental performance.
That is why circular packaging is gaining momentum. It helps companies rethink how packaging is designed, used, recovered, and reintroduced into the value chain.
In this article, you will discover what circular packaging means, why it matters, what its main characteristics are, and how companies can implement more effective sustainable packaging solutions.
In the midst of an environmental crisis that poses significant challenges to society, circular packaging is positioned as a company strategy to face it and successfully reduce waste production.
In this context, we should not ignore the effort made by the plastic production companies to minimize the commercialization of disposable plastic products manufactured for a single use, investing in new technologies and formats aligned with circular economy principles.
More specifically, in Spain, the new Law and Regulationson Waste aim to "minimize the negative effects of waste generation and management on human health and the environment (...) and make efficient use of resources", urging companies to adopt recyclable packaging solutions and consumers to choose its use and incorporate recycling practices into both domestic and industrial environments.
The Spanish ACTION PLAN FOR THE IMPLEMENTATION OF THE 2030 AGENDA in Spain, defines the Circular Economy as "oriented to the change from a traditional linear system,- extracting, producing, consuming and disposing - towards a sustainable framework that maximizes the utility of materials and energy resources, minimizing the generation of waste."
It is true that the statistics indicate an increase in recycling rates, but it is also true that it will take a little more effort to achieve the planned objectives. Circular packaging is emerging as a great ally and part of the solution.
After all, packaging is what visually impacts the consumer, which causes a product to be chosen or rejected on numerous occasions. This type of circular packaging responds to a new concept based on eco-design and packaging management under the principles of circular economy, an initiative that minimizes waste and optimizes the use of resources throughout the life cycle of a product, including its packaging.
From this perspective, the circular approach implies a concept, design, production and management of packaging focused on reducing the consumption of materials to the maximum, promoting their reuse and recycling while always minimizing the environmental impact.
Circular packaging has certain qualities and characteristics that give it its own entity. To know them allows us to understand their role and impact on the circular economy and environmental protection.
The key is to promote recycling with the aim of minimizing or even eliminating waste. It is true that the end user plays an essential role in this chain because, in general, the problem is not so much the material itself, but the abandoned and poorly managed waste.
Circular packaging relies on smart design. Packaging should be developed to minimize material consumption while still protecting the product effectively. It should also be easier to sort, recycle, or reuse after its first life cycle.
This is where eco-design becomes essential. Good design decisions can improve packaging performance while reducing waste and simplifying recovery.
Material selection has a direct impact on circularity. Circular solutions prioritize materials that can be recycled, reused, or sourced from renewable or recycled content.
This is especially relevant in the conversation around new plastics. The challenge is not only to reduce dependence on virgin fossil-based materials, but also to develop packaging solutions that fit better into existing recovery systems and support long-term circularity.
Where possible, circular packaging should support multiple uses. Reusable formats, refill systems, and return models can help packaging stay in circulation for longer and reduce the need for single-use alternatives.
Even the best packaging design needs an effective recovery system behind it. A circular approach integrates collection, sorting, recycling, traceability, and collaboration across the entire value chain.
The circular economy is a model of exploitation of resources that promotes the optimization of products and their materials, maximizing the useful life of the container, promoting its reuse and favoring recycling.
The objective is to reduce the large volume of waste generated by each inhabitant, through the use of recyclable materials, in addition to proper waste management.
In Spain, the Circular Economy Strategy 2030 seeks to promote a new model of production and consumption where raw materials, products and resources remain in the economy for the longest time and waste generation is reduced.
This strategy contributes to generating a more sustainable future for the planet, prioritizing avoiding pollution as much as possible and advocating for a sustainable, decarbonized, resource-efficient and competitive economy.
In this friendlier horizon, circular packaging plays a central role, especially if we consider the greatenvironmental pollution that waste from excessive packaging produces today.
Companies are beginning to assume their obligations in pursuit of the circular economy thanks to these current regulations and a greater social awareness about respect and care for the environment.
The TRACEPACK project, supported by the consultancy HEURA and the SCRAP AEVAE, seeks to work on the optimal management of packaging from the professional agricultural products sector.
Specifically, its main objective is to recycle packaging waste from this sector and to manufacture new packaging to be used by this same industry.
To ensure the success of the project, all actors involved in the production and waste management chain participate, including users and intermediaries.
Accordingly, this closed-loop involves multiple actors across the chain:
APS -Alcion Packaging Solutions is actively developing circular packaging, through its R+D+i technical department, including barrier packaging solutions compatible with 100% mechanical recycling processes.
In particular, technologies like plasma coating enables high-performance packaging suitable for hazardous chemical products while keeping full recyclability.
Enter the circularity! Further details are available in our catalogue!
Do get in touch with our team to clear doubts and use our sustainable packaging.
On November 14th, the IV APS’ Open House Days brought together clients, suppliers, and partners in a space dedicated to sharing knowledge, experiences, and a strategic perspective on the current challenges facing the chemical industry in plastic packaging.
This highly significant event for our sector featured professional presentations covering topics ranging from the role of packaging in chemical filling lines to control parameters, critical adjustments, and future projections.
Below, we share a summary of the main topics addressed during this edition.
The day began with a presentation dedicated to understanding the role of plastic packaging within a complex production system, such as chemical filling lines.
It was emphasized that packaging is not a passive element but a functional component that directly influences efficiency, safety, and the final product quality.
During the presentation, the key properties determining packaging performance were discussed: chemical resistance, mechanical behavior, compatibility with different formulations, and dimensional stability under temperature variations.
The focus was also placed on how an optimized design can reduce waste, streamline processes, and contribute to sustainability through the use of more efficient and recyclable materials.
Attendees were shown concrete examples of how improvements in packaging engineering generate positive impacts across the entire production chain, from filling to storage and transportation.
In short, a successful chemical filling line requires machinery and packaging to work together. That is where packaging quality lies.
Keep learning: Plastic container and packing line: how to achieve efficient integration
Another central focus of the event was the analysis of adjustment and control parameters that ensure reliable and safe operation in chemical filling lines.
The presentation delved into the need to implement precise control systems to ensure process repeatability, minimize deviations, and optimize production times.
Key topics addressed included:
In addition, real-life cases were presented in which small variations in settings caused significant differences in productivity, highlighting the need for continuous training and constant monitoring to ensure process reliability.
The technical adjustment of caps was another key topic, as it represents a critical point for ensuring the safety of the final product and preventing accidents and significant economic losses.
The presentation explored how cap design, torque, packaging quality, and the compatibility between these elements determine closure performance under real-world conditions.
In addition to explaining the possible variations in materials, geometries, and tolerances and analyzing their effect on sealing, emphasis was placed on the fact that the closure must be an element that adds value to both the packaging and the company.
Best practices for adjusting capping machines were also highlighted, depending on the type of thread and the contents to be packaged, particularly for chemical products that require maximum containment.
The goal is to prevent common issues in applications, such as misalignment.
Keep learning: Caps and closures for industrial plastic packaging: Technical keys for efficient performance
Labeling efficiency was addressed from a comprehensive perspective, linking packaging design, label quality, and machine precision.
The presentation examined the particular challenges of working with chemical product containers, which often have complex surfaces or require specific materials to ensure proper adhesion.
It was emphasized that in the phytosanitary sector, labeling is not merely decorative—it is critical information: warnings, composition, traceability, codes, dates, etc. A single error can entail legal, economic, and safety risks.
As a result, the main parameters to adjust on labeling machines—speed, pressure, alignment, and material tension—were analyzed, along with their impact on the final result.
It was noted that labeling performance largely depends on the packaging itself. Its geometry, material, and surface quality determine whether the label remains stable, legible, and free of defects.
When packaging is well-designed for labeling, line efficiency and profitability are maximized. Therefore, the label must be designed for the packaging and vice versa.
A poor combination can lead to failures, which always result in additional costs. Conversely, a correct selection prevents problems from the outset.
Participants were also shown concrete optimization examples, where a joint review between packaging and machinery suppliers improved product aesthetics, reduced rejects, and increased operational efficiency.
To close the day, the APS team shared with attendees a strategic vision for the company’s future. The improvements implemented over the past year were reviewed, particularly in process innovation, quality, and customer service.
Emphasis was also placed on the progress of internal projects related to technological modernization, automation, and the continuous improvement of production capacity.
At APS, we are committed to growth and innovation. That is why we aim to continue shaping the future through next-generation packaging that prioritizes quality and safety.
Significant developments are on the horizon, which will strengthen our position as a leading provider of packaging solutions for the chemical industry.
We invite you to stay tuned to our social media channels and website to be the first to know about the new challenges we will be working on!
The container weight has become increasingly important in today’s context, where sustainability, efficiency, and cost reduction are top priorities across production and logistics chains.
Weight optimisation not only implies economic advantages but also contributes to a lower environmental impact — a key concern for many environmentally conscious companies and consumers.
We invite you to learn much more in the following article!
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Talking about container weight means understanding the total mass of a packaging unit, whose role now goes far beyond simply holding a product.
It must protect, ensure product stability, and withstand mechanical stress during storage and transportation—making the distribution process more efficient across diverse sectors such as food, chemicals, or pharmaceuticals.
However, container weight is not a simple figure. It involves multiple variables that influence its final value and affect how the industry perceives sustainability and operational efficiency—while never compromising on safety.
It is essential for industrial companies to consider the factors that influence container weight in order to make smart decisions and make the best choice around their products and budget.
Let’s see what the main variables are:
Get to know more about us: Alcion Packaging Solutions: 80 years of innovation and leadership in the plastic packaging industry
Container weight is not only a reflection of material costs, but also has a direct impact on operational and logistical efficiency—two critical factors for the competitiveness of any industrial company.
Transportation is one of the most expensive and polluting phases of the supply chain.
Reducing container weight improves payload efficiency by optimizing load capacity and reducing travel distances.
This results in lower fuel costs, a reduced carbon footprint, and a more efficient and sustainable logistics management.
Lighter containers also simplify the manufacturing process, as they require less energy for filling, sealing, and handling.
Additionally, reducing container weight helps decrease machinery wear and makes production lines more efficient, enabling higher speeds and lower energy consumption.
Reducing the container weight also leads to a decrease in raw material consumption, resulting in less waste generated throughout the product’s life cycle.
Sustainable containers are easier to recycle, which extends their lifespan and supports a circular economy. Minimizing industrial waste helps meet environmental goals and lowers costs associated with waste management.
Keep learning: Mechanical recycling: What is it and how does it enhance the circularity of packaging?
Reducing the container weight improves operational aspects of production and logistics, while also providing competitive advantages and aligning with global regulations and trends in efficiency and sustainability.
In fact, lowering the net content of containers brings significant benefits for companies.
Today, innovation in materials and design makes it possible to create lightweight yet strong and functional containers that help reduce the environmental footprint of production.
This enhances sustainability while ensuring resistant and functional packaging solutions.
Lower container weight means less material consumption, reducing raw material and production costs.
It also lowers expenses related to transportation and storage, improving the overall profitability of the supply chain.
More and more countries and global organizations are establishing strict regulations on the use of plastics, waste, and emissions.
Reducing container weight helps meet these requirements while positioning companies as responsible and committed to sustainability, enhancing their brand image and facilitating access to increasingly regulated markets.
At APS, we offer a wide range of solutions that meet any plastic packaging needs across the most demanding industrial sectors. Our industrial packaging for chemical products is continuously analyzed to achieve optimisation, always keeping safety at the forefront, as it is essential in this sector.
We provide tailored solutions for each company, delivering packaging adapted to specific requirements, backed by all the guarantees of an approved product and our efficient production capabilities with tight lead times.
At Alcion Packaging Solutions, we address any technical and aesthetic demand, and tackling container weight is no minor detail. Controlling and reducing the weight of packaging is not only feasible but necessary in today’s context, where cost efficiency, regulatory pressure, and environmental responsibility are key drivers.
Let us work with you to find the perfect balance of safety, functionality, and sustainability in your projects.
Alcion Packaging Solutions has long stood as a hallmark of transformation and innovation within the plastic industry.
Celebrating 80 years in operation is a remarkable achivement - one attained by only a select number of enterprises. Established in 1945, ALCION began as a modest Bakelite processing workshop and has since evolved into a globally recognised manufacturer of rigid plastic packaging. This journey has been underscored by a commitment to forward-thinking innovation, continuous investment in technology, and an enduring dedication to quality and sustainability.
The company’s progress is underpinned by a highly capable and committed workforce - comprising machine operators, engineers specialising in in R&D and industrial processes, logistics professionals, human resources specialists, and commercial technicians. Each member of the Alcion team has brought expertise and professionalism to bear, ensuring our packaging consistently meets the most stringent standards. A culture of cross-functional collaboration and transparent communication has been pivotal in maintaining our position as a leader in the sector for eight decades.
As we mark this anniversary, we take great pride in our legacy, reaffirm our commitment to the present, and look to the future with confidence and ambition.
We warmly invite you to discover the spirit of innovation in the plastic industry that defines Alcion Packaging Solutions!
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ALCION’s continued success is rooted in its ability to embrace evolution, innovation, and provide solutions that enhance the functionality, safety, and environmental performance of plastic packaging. In the current climate — where sustainable innovation is more vital than ever — Alcion remains at the forefront.
Historically, the company has specialised in packaging solutions tailored to the industrial sector, with particular expertise in the chemical and agrochemical industries. This specialist knowledge has enabled us to design and manufacture high-performance packaging, safe and efficient solutions that adheres to the most rigorous international regulations.
As new regulatory frameworks drive a shift towards more sustainable materials, Alcion remains proactive — developing forward-looking packaging solutions aligned with environmental best practices.
Since our inception, we have prioritised innovation and responsiveness to both societal expectations and market trends, continuously designing packaging systems that shape the industry’s future.
Find out more information: Alcion Packaging Solutions: manufacture of custom plastic packaging
A cornerstone of Alcion’s sustainability strategy is the integration of recycled materials into our production processes, all of which are certified in accordance with UNE-EN 15343.
This approach significantly contributes to the reduction of our carbon footprint and supports the principles of a circular economy — where materials are reused and given new life. We have consistently invested in the development of techniques that enable the use of recycled content without compromising the structural integrity or performance of the final product.
Alcion is regarded as a leading manufacturer of sustainable barrier packaging solutions, which provide optimal protection against environmental factors such as light, humidity, oxygen, and temperature fluctuations.
Through advanced multi-layer coextrusion technologies and plasma barrier treatment, we produce packaging that effectively mitigates risks of degradation, leakage, or deformation — ensuring the safe and stable storage of sensitive products.
Creating packaging that provides practical and efficient solutions for storage and transportation is at the core of APS.
Our packaging is developed with ease of use, storage, and transport in mind — ultimately improving both operational efficiency and the user experience. This focus not only reduces waste and costs, but also contributes directly to our sustainability goals and supports our customers’ logistical and commercial needs.
Alcion’s sustained leadership in innovation in the plastic industry is largely attributable to our early and ongoing adoption of advanced, sustainable production technologies.
Our Aldaia production facility was established with blow moulding as its foundational technology. This enabled the manufacture of HDPE containers suitable for a range of markets — including cosmetics, personal care, household detergents, and certain chemical and agrochemical products — all while maintaining high recyclability standards.
This division, implemented alongside the blow extrusion section, is responsible for the production of closures and complementary components that optimise the performance of our packaging systems. The injection moulding process ensures precise fit, enhanced sealing, and overall product integrity.
The coextrusion process allows for the manufacture of multi-layer structure by extruding several polymers simultaneously. One or more of these layers may feature barrier properties, resulting in robust packaging suitable for hazardous materials and compliant with ADR certification. This process represents a significant technological advancement, improving resistance and barrier properties.
Keep learning: Keys and advances of sustainable plastic packaging
The introduction of plasma technology in the 21st century has marked a turning point in our manufacturing capabilities. This method enables the creation of single-layer HDPE packaging with enhanced barrier properties, while maintaining full recyclability. Plasma treatment accelerates the surface coating process, yielding high-performance packaging with a lower environmental impact.
Thanks to this innovation, ALCION was awarded the GOLDPACK Prize for Best Circular Economy Project in 2024, highlighting its leadership in implementing sustainable technologies in plastic barrier packaging manufacturing.
Alcion Packaging Solutions’ greatest commitment to achieving innovation in the plastic industry is prioritizing socio-environmental responsibility and sustainability.
Alcion is deeply committed to the continuous pursuit of a circular economy.
Our packaging is designed based on certain eco-design parameters, and its production is environmentally friendly, prioritizing recycling and optimized shipping services to reduce environmental impact.
Fully aware of its commitment to sustainable development and its contribution to the circular economy, Alcion has achieved and maintains important certifications in line with the highest international standards:
With 80 years of experience behind us, ALCION remains steadfast in its investment in research and development, always seeking to stay at the cutting edge of innovation and sustainability.
On this landmark anniversary, APS celebrates not only a distinguished past but a future filled with opportunity and progress. We reaffirm our role as a benchmark in the global plastic packaging industry and commit to continued excellence in innovation, quality, and environmental stewardship.
Alcion is your perfect partner in plastic packaging innovation - helping shape a more sustainable future, together
In the plastic packaging manufacturing industry, controlling specific technical parameters is key to ensuring functionality, efficiency in use, and the acceptance of the final product. One such parameter, often overlooked at first glance, is the ovality of cylindrical containers.
But what is ovality, and why is it so important?
In this article, we will explore the concept of ovality, its impact, and how it influences the design, production, and performance of cylindrical plastic containers throughout their lifespan.
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Ovality is defined as the deviation from a perfect cylindrical shape. In other words, it measures how close a cylindrical container is to being perfectly round. In the plastic industry, deviations in this parameter can arise from various factors, such as the manufacturing process, material behavior during processing, and even storage or transportation conditions.
Ovality is typically measured by calculating the difference between a containers’ maximum and minimum diameters. It is expressed as a percentage, obtained by dividing this difference by the nominal diameter. High ovality values indicate significant deformation, whereas low values signify a more uniform product. Each container has a defined tolerance limit based on its technical specifications.
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Excessive ovality can hinder the automatic filling processes, as containers may not fit correctly into the machine holders. Additionally, improper shape can cause sealing defects, leading to leaks and product contamination.
Containers with high ovality are less stable, particularly when stacked. This increases the risk of tipping over and sustaining damage during transportation and storage, ultimately affecting customer perception of quality.
In today’s highly competitive market, packaging appearance is crucial. Containers with visible deformations may be perceived as defective or of lower quality, negatively impacting brand image and consumer trust.
Controlling ovality allows for optimized wall thickness, reducing production costs and, consequently, minimising environmental impact by using only the necessary amount of material.
Ovality deviations beyond acceptable limits can hinder proper label application. Labels may wrinkle, shift, or fail to adhere uniformly, affecting product presentation and making critical information, such as ingredients, barcodes, or usage instructions, difficult to read.
Ensuring that ovality remains within acceptable limits requires several key considerations :
In summary, ovality is a critical factor that influences the functionality, aesthetics and efficiency of cylindrical rigid plastic containers. Proper control of this parameter enhances performance across packaging production and distribution processes while reinforcing consumers’ perception of quality. In a highly technical industry, attention to details like ovality can determine or failure a container.
You may be interested in: Sustainable plastic storage of chemicals: An approach to the circular economy and safety
It is essential to remember that a plastic container’s structural integrity is influenced throughout the whole production process, especially as it exists the blow molding station at high temperatures.
At APS, we maintain strict compliance with the ovality parameters defined in our production technical specifications, conducting in-lie checks to detect and correct any deviations. Contact us! Our team will help you find the perfect container for your product!
The GoldPack Awards are an initiative of the Packaging Innovation Cluster and specifically, the Award for the Best Circular Economy Project is proposed to recognize excellent projects in different areas of the business Circular Economy, such as the implementation of sustainable production practices that minimize waste generation and/or promote recycling, among several other aspects.
In its first edition 2024, the jury has recognized ALCION PACKAGING SOLUTIONS as deserving of this award for our Circular Economy Project based on the Implementation of a new technology: Chemical Generation of Barrier by Plasma. A disruptive technology that revolutionizes our field of barrier packaging in terms of recycling and environmental impact, which allows to go from a multi-layer multi-material structure to a mono-material with barrier properties, applying surface treatment using Plasma that provides the protective barrier to the packaging. This has materialized in a new line of plastic containers for the packaging of chemical products, manufactured using a disruptive and pioneering technology in Spain. 5 and 10l jerrycans for the industrial sector and approved for the transport of dangerous goods (UN marking), analysed in the design phase to optimise their behaviour and facilitate the circularity of the packaging.
Multilayer barrier packaging presents a significant challenge in terms of recycling. Although there are possibilities through Chemical Recycling, it involves the use of solvents and is a high-cost process, compared to mechanical recycling. The plasma technology that we have implemented at ALCION appears to solve the recyclability of these barrier containers as it allows them to be recycled 100% mechanically and provide greater environmental benefits, using highly efficient state-of-the-art electrical equipment that, in our facilities, consumes energy of 100% renewable origin. In addition, these containers facilitate a better use of the packaged product. The plasma produces a modification of the surface tension that allows a greater sliding and emptying of the packaged product, reducing the loss of residual product that remains in the container, thus achieving the Objective of offering a Barrier Container integrated into a closed recycling circuit (HDPE).
At ALCION PACKAGING SOLUTIONS we have been working for years to achieve plastic packaging that not only meets the needs of the market, but also contributes to a more sustainable future. This award is for us "a validation of these efforts and a reminder of the importance of continuing on this path", which is why we continue to work on other projects such as the incorporation of recycled materials certified UNE EN 15343:2008 to our packaging that will also be marketed with their corresponding approval for the transportation of dangerous goods (UN marking).
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