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Energy recovery

What is energy recovery (and how does it work)?

Not all stand-up pouches can be reused or recycled. In such cases there are different ways to put the waste to good use. One of them is energy recovery, converting residual waste into heat or electricity through controlled incineration in specially equipped plants.

These plants are designed to recover energy efficiently and to limit emissions as much as possible. So it is not the same as simply burning waste. Although the material itself is lost, the process still contributes to the energy supply, for example for electricity generation or district heating.

Within the European waste hierarchy, energy recovery ranks below reuse and recycling, but above landfill. It is often used as a last step when other treatment routes are not technically or practically feasible.

Energy recovery packaging by incineration – less sustainable alternative

When does a stand-up pouch end up being incinerated for energy recovery?

Multiple layers, mixed materials

Stand-up pouches are typically sent for energy recovery when recycling is not an option. There can be several reasons. In some cases, the pouch consists of multiple layers, such as plastic combined with aluminium or paper. These materials are hard to separate and cannot be recycled as one.

It is also important to realise that recycling cannot be applied 100 percent in every country. Due to limited capacity and infrastructure, many plastics, including stand-up pouches, do not enter the recycling process and are ultimately incinerated.

Contamination

After use, grease, food residues or chemicals can make a pouch unsuitable for recycling. This contamination makes recycling complex and costly, so many pouches are rejected for reprocessing. In addition, many sorting facilities are not yet equipped to process flexible packaging such as stand-up pouches efficiently. Even when pouches are successfully sorted, the contamination often leaves the output too dirty for high-quality recycling.

In such cases, energy recovery is often chosen as an alternative. The packaging material is not completely wasted, but still contributes by producing heat and electricity. This more sustainable option recovers energy from the material.

Chemical substances

Pouches with certain chemical coatings or barrier layers can disrupt the recycling process and reduce the quality of recycled material. These coatings prevent full recyclability by introducing unwanted substances into the material loop. In such situations, controlled incineration with energy recovery offers a more environmentally friendly alternative.

For our pouches, we take recyclability into account through conscious material choices. Our barrier layers, ALOx/EVOH, and functional coatings such as matte or paper-feel varnish always remain below 5% of the total weight. These low percentages help keep our pouches compatible with current recycling systems. For more information about our sustainable material choices, see our pages on recyclability and monomaterials.

What does this mean for your packaging choice?

Energy recovery is not a circular solution, but it can still play a useful role in treating stand-up pouches that are not recyclable. By recovering energy from residual streams, we avoid leaving waste unused or sending it to landfill. At the same time, the material itself is lost, which makes it less sustainable than recycling or reuse.

For companies looking to make their pouches more sustainable, the focus should be on solutions that make recycling possible. Avoid unnecessary combinations of materials, choose monomaterial where it fits, and minimise printing and coatings that complicate processing.

There is no one-size-fits-all approach. What works depends on your product, the level of protection needed, and the options in the chain. Not sure whether your packaging aligns well with waste treatment in practice, feel free to contact us. We are happy to think along with you.

Looking for a quick answer? Check out these FAQs!

Energy Recovery

What is energy recovery for packaging?

Energy recovery means using the energy in residual waste through controlled incineration, generating heat and electricity. You use it when reuse or recycling is no longer possible. It is the last step in the waste hierarchy, after reduce, reuse and recycle. For stand up pouches: first choose mono PE or mono PP and add clear sorting instructions. Only when separation is not possible does energy recovery come into view. Modern facilities operate under strict emission standards and supply heat to district heating networks and electricity to the grid.

Why are some stand up pouches incinerated instead of reused or recycled?

Because some pouches use multilayer combinations that sorting systems do not recognise as a single material, they end up being incinerated. Contamination from food residues, grease, adhesives, labels or windows increases that chance. And in some regions, the infrastructure for sorting and recycling flexible films is still limited, so pouches are not always processed in a high quality way.

How do I design to avoid incineration?

Design your pouch for sorting and recycling to help avoid incineration. Choose mono PE or mono PP, including zipper, valve and label in the same material family, and avoid metallic layers and mixed films where possible. Use as little ink as possible, choose water based adhesives and add clear sorting instructions on the packaging. Keep formats compact and test the thinnest film that still seals well and protects. If you use paper, go for 100% paper and indicate paper recycling, or use paper with PVA if you need heat sealing and it can still be accepted with paper locally.

What role do coatings and barrier layers play in stand up pouches?

When the coating or barrier layer is less than 5% of the total weight, the pouch can often still fit existing recycling streams. This depends on the country, collection system and waste processor. We are happy to review your case and test what works best in practice.

Is energy recovery sustainable?

Energy recovery uses the energy in residual waste through controlled incineration, generating heat and electricity. You apply it when reuse or recycling is no longer possible. It is a last step in the waste hierarchy, after reduce, reuse and recycle. For stand up pouches: first choose mono PE or mono PP and add clear sorting instructions. Only when separation is not possible does energy recovery come into view. Modern facilities operate under strict emission standards and supply heat to district heating networks and electricity to the grid.

Want to know more or have questions? Contact us - we'll be glad to help!