In 2025, the circular economy service provider Interzero processed 2 million metric tons of recyclable materials, thereby avoiding over 900,000 metric tons of greenhouse gas emissions compared to primary production. In addition, over 7.2 million metric tons of primary resources were conserved. For the first time, Fraunhofer UMSICHT also calculated the amount of crude oil saved: By recycling approximately 1 million metric tons of plastics, this amounted to 3 million barrels of crude oil. This corresponds to the volume of about 9.5 million 50-liter fill-ups for passenger cars. The study was prepared in accordance with international life cycle assessment standards (ISO 14040/14044).

Challenges for the yellow bag

The detailed analysis of lightweight packaging collection (LVP) revealed not only positive overall results but also current trends in the packaging market: The proportion of composite packaging and unsorted waste in the yellow bag is increasing. According to Interzero, this trend is often driven by paper packaging with inseparable plastic coatings. Combinations that are difficult to separate—such as plastic containers with cardboard sleeves—also slow down the recycling process, as consumers must separate them by hand. Added to this is the problem of so-called multilayer packaging, in which different types of plastic with varying properties are firmly bonded together. “Packaging that initially appears sustainable turns out to be a disruptive factor in the sorting plant,” says Dr. Markus Hiebel, Head of the Sustainability Management and Participation Department at Fraunhofer UMSICHT. “We need a shift in thinking regarding packaging design so that design and circularity align better and we can keep more materials in the loop. With these raw material sources, companies can, for example, become more resilient and less dependent on fossil-based plastic pellets.”