Packaging with Purpose - Recycling for the next cycle of life

As much as we love our ideas and discussions of snacking, recipes and spices, our packaging system is something equally important to us. When we discussed our packaging options, we asked ourselves: What happens after the packaging fulfills its duty of carrying our snacks? What will its next life look like? 

This question set us on a journey to explore ‘the next cycle of life.’

Inspired by the circular economy—where nothing goes to waste, and resources are treasured like the family heirlooms passed down generations—we dreamed of giving our packaging materials a second, even third, life. Why not a continuous life?  We knew the path wouldn’t be easy. But isn’t that true of all meaningful journeys?

The next life cycle is a sustainable strategy committed to minimizing waste and maximizing resource efficiency. It specifically looks into the phase that comes after the initial use of a product—what happens after the packaging no longer serves its purpose of containing our snacks? The first step in our journey was to consider reuse—a concept as old as Indian households, where a pickle jar becomes a spice container, and an old sari transforms into a quilt. For our packaging, reuse wasn’t limited to a single definition. It also meant repurposing, upcycling, and downcycling, much like how we find new roles for everyday items. We embraced this philosophy in our primary packaging, discussed here -->"From Tradition to Tomorrow - Developing Reusable packaging for Namkeen Queens"

Then, we delved deeper. What happens when reuse is no longer possible? We discovered two  paths for the next life of packaging:

Recycling and Material Recovery -  Extracting used materials and reintroducing them into manufacturing processes.

Composting and Biodegradability – Returning used materials to the earth as nutrients, completing their natural lifecycle.

These two approaches embody the wisdom of the ages—a cycle where nothing is truly wasted, echoing the philosophies of the circular economy and Cradle to Cradle (C2C) design. These two approaches are part of a regenerative "make-use-return" system, supporting the circular economy and C2C methodologies. These frameworks emphasize creating products and systems with continuous lifecycles, where materials function as nutrients circulating in closed loops—either in a technical cycle (reused in manufacturing) or a biological cycle (returning to nature). The goal is to eliminate waste entirely by designing products that can be reused, recycled, or safely decomposed at the end of their lifecycle.

Figure 1: The circular economy butterfly diagram from Ellen MacArthur Foundation (source: Ellen MAcArthur Foundation)

While this is a challenging goal, it serves as our guiding vision for development. Our focus is to increase the chances that our packaging materials will be reused, recycled, or safely decomposed once their service as Namkeen Queens’ packaging concludes.

Recycling: A Practical Perspective

Recycling, like any practice, has its challenges. It’s not enough for a material to be recyclable; the infrastructure must exist for it to be recycled. Recycling and material recovery involves collecting, processing, and remanufacturing discarded materials to create new products or raw materials. The success of recycling is closely tied to local waste management programs. Therefore, in addition to selecting recyclable materials, we also consider the recycling rates of various packaging materials in the U.S.

According to 2018 data from the U.S. Environmental Protection Agency, paper and cardboard have the highest recycling percentage at 80.9%, followed by steel containers and packaging at 73.75%. Next are aluminum containers and packaging at 34.9%, glass containers and packaging at  31.25%, and wood containers and packaging at 26.9%. 

Plastic has the lowest recycling rate at only 13.6%.

This data reminded us of India’s old philosophical traditions emphasizing the importance of careful and respectful use of natural resources: To choose materials wisely, for their future rests in the decision we made. Paper stands out as a promising choice because it is biodegradable and widely recycled. Steel and aluminum, with their robust recycling rates, also offered hope. However, plastic, with its low recycling rates, posed a challenge—a reminder that convenience often comes at a cost.

Figure 2: Recycling rates in the U.S for containers and packaging materials in 2018

We also looked at multilayer flexible packaging, commonly used for snacks like potato chips. While this packaging excels in preserving freshness and reducing costs, its complex composition makes recycling nearly impossible. We’ve also explored alternative materials like banana leaves, mycelium, seaweed, and algae. However, most of these materials are still in the early stages of development, and many are not yet certified for food use.

Our Packaging Material Choices: Tinplate and Kraft Paper

After considering various factors, including design requirements and sustainability goals, we've selected two materials that best align with our needs and values: tinplate containers and kraft paper.

Tinplate container 

Steel has always held a special place in Indian kitchens, from the dabba carrying home-cooked meals to the sturdy spice boxes passed down through generations. Our tinplate containers, made of 99% steel with a thin tin coating, carry forward this legacy. Durable, FDA-approved, and endlessly reusable, they are like a trusted family elder—reliable and enduring. However, we recognize that steel production has a higher carbon footprint compared to plastic, particularly when virgin materials are used. To balance this, we work with suppliers to understand emissions and engage with customers on ways to extend the life of these containers.

Tinplate is 100% recyclable without quality loss, meaning it can be recycled indefinitely. With a recycling rate of 73.75%, it’s one of the most recycled packaging materials in the U.S., making it a suitable choice for our main packaging. We also plan to maintain ongoing communication about best practices for managing these containers once their service life ends.

Kraft paper

Kraft paper is a humble material yet strong, versatile, and eco-friendly. Made from wood pulp, it has the potential to biodegrade naturally or be recycled into something new,  typically containing 70-80% cellulose fibers. For our packaging, we focus on unbleached, uncoated kraft paper for its strength, minimal processing, and end-of-life sustainability. We ensure the paper we use is FSC® certified. Food-grade kraft paper, which meets safety standards and is free from harmful chemicals, is essential for our food packaging.

The beauty of kraft paper lies in its simplicity.  Kraft paper offers multiple disposal and recovery options due to its biodegradability and recyclability. Contamination (e.g. with food or grease) may make recycling less suitable. Luckily, kraft paper has a versatile end-of-life profile because composting is its next eco-friendly option. Thus, it can be recycled or composted depending on the surface condition. Paper and paperboard have the highest recycling rates in the U.S. (80.9% in 2018). Recycling paper not only reduces deforestation but also helps conserve forests and biodiversity. 

Paving the Path to Recycling and Material Recovery 

Recycling and material recovery are crucial for a sustainable future. By diverting materials like paper and steel from landfills, we reduce the need for raw material extraction and lower greenhouse gas emissions (e.g. by conserving energy in manufacturing). Material recovery transforms waste into valuable resources, fostering a circular economy where materials are reused, reducing environmental impact.

This is just the beginning of our journey. We plan to improve many aspects of our packaging and product lifecycle. We’re committed to building a snack experience that is both authentic and sustainable. Stay tuned for our next article, where we will explore the second option in the next cycle of life for our packaging materials: composting and biodegradability.