Downgauging Plastic Packaging

The Smart Way to Cut Waste, Costs & Carbon

In the race toward sustainability, businesses are constantly seeking ways to reduce their environmental impact without compromising product quality or consumer satisfaction. One of the most effective, and surprisingly simple, strategies is downgauging: reducing the thickness of plastic packaging films.

But downgauging isn’t just about trimming microns. It’s about rethinking packaging from the ground up, unlocking savings, improving efficiency, and aligning with modern consumer values.

What Is Downgauging?

Downgauging means reducing the thickness of plastic film used in packaging, while still maintaining the pack’s integrity throughout its lifecycle, from production to shelf to home. It’s not about cutting corners; it’s about finding the minimum operational thickness that still delivers performance.

Whether you're using single web films or laminates, downgauging can be applied across a wide range of packaging formats.

Examples:

• Morning goods wrapped in 25-micron polypropylene can be downgauged to 20 micron, saving 20% in material.
• Laminates like 12-micron polyester + 50-micron PE for pulses can be reduced to 40-micron PE, cutting thickness by 16%.

Why It Matters

Downgauging offers a triple win:

Environmental Benefits

• Less plastic used = less waste.
• Lower carbon footprint from production and transport.
• Supports sustainability goals and ESG reporting.

Economic Benefits

• More packs per kilo of film.
• Fewer machine changeovers due to longer reels.
• Reduced material costs.

Operational Benefits

• Improved line efficiency.
• Less downtime.
• Enhanced sealing consistency.

Real-World Success: Bakery Case Study

A large UK bakery using 100 tonnes of 25-micron OPP annually made the switch to 20-micron film. The result?

• 20 tonnes of plastic saved per year.
• 25% fewer machine changeovers.
• Significant cost savings.
• Improved operator confidence thanks to modern film strength.

This wasn’t just a technical win, it was a cultural shift. Operators who had previously resisted thinner films due to past failures embraced the change, supported by advances in technology and on-site engineering expertise.

Changing Perceptions

Historically, downgauging was avoided due to fears that thinner packaging would feel “cheap” or “flimsy.” But today’s consumers are more informed and eco-conscious. A lighter pack is no longer a liability; it’s a badge of sustainability.

Brands can now use downgauging as a marketing message, showcasing their commitment to reducing plastic and protecting the planet.

Beyond Thickness: Smarter Packing

Downgauging isn’t just about microns, it’s also about optimising pack design. Many operators use the same film width across different products, leading to excess film in seals, inconsistent sealing, and wasted material.

By tailoring film width and format to each product, companies can:

• Improve pack aesthetics.
• Enhance shelf life.
• Cut waste and cost.

Ready to Start?

We offer FREE Sustainability Packaging Audits to help businesses identify downgauging opportunities. Our technical engineers visit your site, assess your packaging, and provide tailored recommendations to help you meet your sustainability goals.

As Kevin Vyse, UK Government Packaging Advisor, puts it:

“Trying to keep the customer happy whilst doing the practical, scientific thing has become almost impossible. Switch to paper, card, metal or glass and all the time you are adding carbon. I guess the question is: what problem are you trying to solve?”

Downgauging helps solve multiple problems—without creating new ones.

08 | 09 | 2025