Why Recyclable Dried Fruits And Nuts Packaging Costs More

As sustainability regulations tighten and consumer awareness grows, recyclable packaging for dried fruits and nuts has become a top priority for brands in Europe, North America, and Australia. However, many food brands and importers quickly notice one thing: recyclable dried fruits and nuts packaging often costs more than traditional plastic packaging.

So why does this happen? And is the higher cost justified in the long term?

This blog breaks down the real reasons behind the higher cost of recyclable dried fruits and nuts packaging, helping brands make informed decisions when transitioning to sustainable packaging.

1. Advanced Recyclable Materials Cost More Than Conventional Plastics

Traditional dried fruit and nut packaging often uses multi-layer plastic laminations (PET/PE, OPP/CPP, PET/AL/PE) that are cheap to produce but impossible to recycle.

In contrast, recyclable packaging typically uses:

• Mono-material PE or PP structures

• MDO-PE films

• Recyclable barrier coatings instead of aluminum

• PCR (Post-Consumer Recycled) content

These materials require:

• Higher-grade resin

• Specialized film extrusion

• Strict material consistency

As a result, raw material costs for recyclable packaging are significantly higher than conventional plastics.

2. Barrier Performance Requires More Sophisticated Engineering

Dried fruits and nuts are highly sensitive to:

• Oxygen

• Moisture

• Light

• Oil migration (especially for nuts)

Recyclable packaging must achieve high barrier performance without using aluminum foil, which increases cost due to:

• Advanced coating technology (EVOH, ALOx alternatives)

• Multi-step film processing

• Tighter quality control

Maintaining shelf life, flavor, and freshness while staying recyclable is technically challenging—and that expertise adds value and cost.

3. Lower Production Efficiency and Higher MOQ Constraints

Recyclable packaging structures are still evolving. Compared with traditional films, they often have:

• Lower machine running speeds

• Higher waste rates during setup

• Stricter sealing and forming requirements

Additionally:

• Fewer factories can produce certified recyclable packaging at scale

• Minimum order quantities (MOQs) are often higher

• Small or custom orders carry higher unit costs

This is especially noticeable for custom printed dried fruit and nut packaging bags.

4. Sustainable Printing and Inks Increase Overall Cost

Eco-friendly packaging often uses:

• Low-migration inks

• Water-based or solvent-reduced inks

• Reduced ink coverage designs

• Cleaner production processes

These printing methods are more environmentally responsible but also more expensive than conventional printing, especially for small batch orders.

5. The Long-Term Value Outweighs the Short-Term Cost

While recyclable dried fruits and nuts packaging costs more upfront, it delivers strong long-term benefits:

• Enhances brand sustainability image

• Aligns with retailer and distributor requirements

• Reduces regulatory risk

• Meets growing consumer demand for eco-friendly packaging

• Supports premium pricing strategies

Many brands successfully offset packaging cost increases by:

• Optimizing packaging structure

• Reducing material thickness

• Improving supply chain efficiency

• Positioning products as sustainable or premium

Recyclable Packaging Is an Investment, Not Just a Cost

Recyclable packaging for dried fruits and nuts is more expensive because it requires higher-quality materials, advanced engineering, stricter compliance, and sustainable production practices.

However, for brands targeting eco-conscious consumers and international markets, recyclable packaging is no longer optional—it is a strategic investment in brand growth and future compliance.

At Bio Pack, we specialize in custom recyclable packaging solutions for dried fruits, nuts, and organic food brands, helping clients balance sustainability, performance, and cost.

If you are planning to upgrade your dried fruits or nuts packaging, contact our team to explore recyclable structures tailored to your market and budget.