9 Things to Avoid When Designing Compostable Packaging

Designing compostable packaging from scratch looks straightforward. Pick a compostable material (paper, bagasse, PLA), design the form factor, print the brand. Done.

In practice, several common mistakes can take a well-intentioned design and turn it into a product that doesn’t actually compost, contaminates organics streams when consumers try to compost it, or fails performance tests during normal use. The compostable packaging design field has accumulated specific lessons over the past 15 years about what works and what doesn’t.

This guide walks through nine specific things to avoid when designing compostable packaging, with explanations of why each matters and how to avoid them.

1. Mixing materials within a single product

The most common mistake: combining compostable and non-compostable materials in one piece of packaging.

Examples:
– A compostable paper cup with a plastic lid
– A bagasse plate with a non-compostable foil sticker
– A compostable bag with a plastic zip closure
– A paper-and-PLA cup with a plastic-coated label

Why it matters: Composting facilities can’t easily separate materials. If a product is part compostable and part not-compostable, the whole product often gets rejected from organics streams. The compostable material that could have composted ends up in landfill alongside the non-compostable part.

How to avoid: Design the entire packaging unit from compostable materials. If a lid is needed, use a compostable lid. If a label is needed, use a compostable label. Every component of the package should compost together.

2. Using non-compostable adhesives

Adhesives are easy to overlook. A “compostable paper bag” with plastic adhesive at the seams isn’t fully compostable.

Common problem adhesives:
– Synthetic glues (most modern adhesives)
– Plastic-based tape
– Hot melt adhesives that contain synthetic polymers
– Pressure-sensitive adhesives with non-biodegradable backings

Compostable alternatives:
– Starch-based adhesives
– Casein-based adhesives (milk protein)
– Some natural latex adhesives
– Heat seals (no adhesive, just heat-bonded fibers)

Why it matters: Adhesives in commercial composting facilities don’t fully break down. They can leave residue or contamination in the finished compost. For certification (BPI, OK Compost), the adhesives need to be compostable too.

How to avoid: Specify compostable adhesives at the design stage. Confirm with manufacturers what adhesives are being used. Get certifications that cover adhesive choice.

3. Foil and metallic finishes

Foil — even thin foil — is metal. Metal doesn’t compost.

Common foil applications:
– Embossed metallic logos
– Hot-stamp metallic text
– Foil-laminated paper for visual effect
– Metallic ink (some inks use metal particles for shine)

Why it matters: The metallic surface looks premium but introduces material complexity. Even a small amount of foil contaminates the compost stream.

Compostable alternatives:
– Non-metallic gold/silver effects through paper color and printing
– Metallic-effect printing using non-metal pigments (some pigments achieve metallic appearance through structural color)
– Embossing (no metal) for visual texture without metal

How to avoid: Design without metallic surfaces. If a “premium” look is needed, achieve it through paper quality, typography, embossing, or printing technique — not foil.

4. Deep ink coverage

Heavy ink coverage on compostable packaging creates several problems:

Issues:
– Ink contains pigments and binders that may not fully biodegrade
– Heavy ink coverage can interfere with moisture absorption, slowing composting
– Some inks (especially metallic and fluorescent) have biocompatibility concerns
– The cost of printing increases with ink coverage

Why it matters: Compostable packaging needs to actually compost in commercial facilities. Heavy ink coverage slows that process. For BPI certification, ink choices may affect approval.

Compostable alternatives:
– Use lighter ink coverage, with negative space showing the natural paper
– Use vegetable-based inks (soy, linseed) rather than petroleum-based
– Use water-based inks rather than solvent-based
– Reserve heavy ink for areas where it’s necessary; use line art or minimal text elsewhere

How to avoid: Aim for under 30% ink coverage on compostable packaging. Use compostable-rated inks (some manufacturers explicitly label their inks as compostable-compatible).

5. Over-engineering the design

Compostable packaging works best when designs are simple. Over-engineered designs often combine multiple materials and complicated structures.

Examples of over-engineering:
– Multi-layer composite construction (paper + foam + plastic + paper)
– Elaborate clip and snap mechanisms (sometimes plastic)
– Decorative add-ons (ribbons, tags, plastic decorations)
– Custom-shaped pieces that require multiple molds/dies

Why it matters: Complex designs create:
– More opportunities for non-compostable material contamination
– Higher manufacturing costs
– Difficulty in standardization and procurement
– Greater design risk if compostability testing fails

How to avoid: Start with simple shapes. Use standard manufacturing processes (paper folding, bagasse molding, PLA molding). Add complexity only where it adds value.

6. Insufficient material thickness

Compostable packaging that fails during use is worse than no compostable packaging. If a cup leaks, a plate breaks, or a bag tears, the customer experience is worse than with conventional packaging, and the customer may decide compostable foodware is unreliable.

Common failure modes:
– Bagasse plates too thin to hold weight of food
– PLA cups too thin to maintain rigidity at room temperature
– Compostable bags too thin to hold contents during normal use
– PLA-lined paper cups with too-thin lining (leaks)

Why it matters: Failed performance damages the brand and the broader compostable foodware category. A customer who has a bad experience with one compostable item is less likely to buy others.

How to avoid: Specify minimum thickness based on the use case. Test prototypes with realistic loads and contents. Don’t optimize for lightest weight if performance is at risk.

7. Lack of certification

A product labeled “compostable” without certification is a credibility problem. Customers, regulators, and compost facilities increasingly require verifiable certification.

Required certifications:
– BPI (Biodegradable Products Institute) for US markets
– TUV Austria OK Compost INDUSTRIAL for European industrial composting
– TUV Austria OK Compost HOME for home composting
– ASTM D6400 compliance

Why it matters:
– Compost facilities are increasingly refusing uncertified materials
– California SB 343 and similar laws require verifiable claims
– Brand credibility depends on real verification, not marketing claims

How to avoid: Plan for certification from the design stage. The certification process takes time (often 6-12 months) and money ($10,000-50,000 depending on product and certifier). Don’t launch products without certification if compostability is part of the marketing.

8. Ignoring the disposal pathway

Compostable packaging only delivers environmental benefit if it actually ends up in commercial composting. A compostable cup that goes to landfill is just a more expensive disposable cup.

The pathway consideration:
– What disposal infrastructure will the customer have?
– Is curbside organics available in their region?
– If not, what will the customer do with the product?

Why it matters: Designing for compostability without considering the disposal pathway is incomplete. The product exists in a system, not in isolation.

How to avoid: Consider the disposal pathway during design:
– For regions with organics infrastructure: standard compostable design is fine
– For regions without: include “industrial compostable” labels prominently, and consider whether home-compostable alternatives are available
– For products that will reach both: design for the worst case (assume some products will be landfilled)

The packaging itself can include language like “Industrial compostable. Look for commercial composting in your area” to set realistic expectations.

9. Forgetting about the entire packaging system

Most products don’t have just one piece of packaging. There’s the primary container, plus shipping packaging, plus retail display packaging.

Common system gaps:
– The product is compostable but the shipping carton uses plastic tape
– The compostable container ships in a non-compostable plastic-wrap multipack
– The retail display has compostable products but plastic divider trays
– The retail packaging uses non-compostable shrink wrap or polybag protection

Why it matters: The customer-facing claim (“compostable!”) is undermined by the broader packaging system. If 80% of the product reaches the customer through plastic, the compostable component matters less.

How to avoid: Design the entire packaging system to be compostable. Use:
– Compostable mailers and shipping boxes (kraft, recycled cardboard)
– Compostable shipping tapes (paper-based)
– Compostable display packaging
– Bulk packing materials (kraft paper, biodegradable peanuts) instead of plastic

The full-system compostability is harder to achieve but more credible.

Practical advice for designers

For a designer working on a new compostable packaging project, a few practical steps:

1. Start with the disposal pathway. Understand what disposal infrastructure your customers will have. This shapes everything else.

2. Pick one material family. Don’t mix unless absolutely necessary. A package made entirely of bagasse and bagasse-compatible adhesives is simpler to certify than a hybrid.

3. Get certification commitments from suppliers. Before finalizing design, verify the materials and adhesives are compostable-rated. Some suppliers can provide test data.

4. Test the product in commercial composting conditions. Lab tests are the official certification path. Field tests (sending packaging to a real compost facility) reveal real-world behavior.

5. Design simple. Complex designs add risk and cost. Simple designs that fully compost are better than complex designs that partially compost.

6. Document the supply chain. If you make compostable claims, you should be able to trace materials back through suppliers. Have documentation.

7. Test the packaging in actual use. A compostable cup that leaks at typical use isn’t a viable product, regardless of compostability.

8. Plan for testing iterations. Most compostable products go through several design iterations before they’re ready for market. Budget time for refinement.

What to look for in a supplier

For brands sourcing compostable packaging from a supplier rather than designing in-house, key questions:

• Certifications: What certifications does the supplier hold? BPI? OK Compost? Independent testing data?
• Material details: What specifically are the materials? Where are they manufactured? Are there sustainability certifications upstream?
• Adhesive specifications: What adhesives are used? Are they compostable?
• Ink and printing details: What ink types? What ink coverage limits?
• Quality consistency: What testing does the supplier do to ensure consistent product performance?
• Production capacity: Can the supplier handle your volume requirements?

A good supplier provides clear answers to these. A supplier that’s vague on materials or certifications is a risk.

The certification process specifically

For brands planning to certify compostable packaging:

BPI certification process:
1. Engage with BPI directly
2. Submit product samples for laboratory testing
3. Provide formulation details (materials, adhesives, ink)
4. Pass disintegration testing (90% disintegration in 12 weeks)
5. Pass biodegradation testing (60% biodegradation in 6 months)
6. Receive BPI certification and right to use logo

Timeline: 6-12 months from submission to certification.
Cost: $10,000-25,000 for typical products. Larger or more complex products higher.

Once certified, ongoing requirements:
– Annual renewal
– Quality control testing on production batches
– Right-to-use the BPI logo on packaging
– Inclusion in BPI’s product database

Other certifications (OK Compost, ASTM compliance) have similar processes.

What this means for the broader market

For the compostable foodware market, the design considerations above shape what products are actually available. Manufacturers that get the design right produce products that:
– Actually compost in commercial facilities
– Pass certifications reliably
– Perform in normal use
– Match customer expectations

Manufacturers that get the design wrong have products that:
– Fail in real composting conditions
– Lose certifications or never gain them
– Have performance issues in use
– Create customer disappointment

For commercial buyers evaluating compostable foodware suppliers, the design quality is one of the things that distinguishes leaders from laggards. The leaders have refined their products over years of learning from these specific design challenges.

The bottom line

Compostable packaging design is more involved than substituting one material for another. The nine considerations above represent learned lessons from the industry’s evolution:

1. Don’t mix compostable and non-compostable materials
2. Use compostable adhesives
3. Avoid foil and metallic finishes
4. Limit ink coverage and use compostable inks
5. Keep designs simple
6. Ensure adequate material thickness for performance
7. Get certified
8. Consider the disposal pathway
9. Design the entire packaging system, not just one component

Getting all nine right produces a product that’s actually compostable, performs in use, can be certified, and delivers the environmental benefit promised in marketing. Getting some wrong produces a product that exists in the “compostable but not really” gray zone — present in the market but not delivering on its claims.

For brands serious about compostable packaging, the design quality matters. The investment in getting it right pays off in customer trust, regulatory compliance, and actual environmental impact.

For B2B sourcing, see our compostable skewers & picks catalog.

Verifying claims at the SKU level: ask suppliers for a current Biodegradable Products Institute (BPI) certificate or an OK Compost mark from TÜV Austria, and check that retail-facing copy meets the FTC Green Guides qualifier requirement on environmental claims.