Broadway Helps Companies Avoid UK Plastic Packaging Tax by Embracing PCR

As plastic moulders and brand owners embrace circularity principles, the use of post-consumer recycled (PCR) plastics continues to grow. A key driver behind this shift is the UK Plastic Packaging Tax (PPT), introduced in April 2022. The tax, initially set at £200 per tonne, applies to plastic packaging containing less than 30% PCR content. This tax incentivises the use of recycled plastics, promoting material circularity and supporting the recycling industry. April 2025 sees the PPT rate rise to £223.69 per tonne.

The benefits and challenges of using PCR

Using recycled plastics offers significant environmental benefits. It reduces plastic waste and reliance on virgin polymers. It can also lower a product’s carbon footprint, as recycled materials are typically less carbon-intensive to produce. However, challenges include difficulties in achieving desired colours and special effects and in maintaining colour consistency. Recycled plastics have residual hues and batch-to-batch variations, making colour consistency harder to control, especially for bright or translucent colours.

On-Site colour matching

Broadway, a trusted UK masterbatch manufacturer, offers solutions to help brands and moulders incorporate more PCR into their packaging. Broadway’s expertise in colour formulation helps mitigate the aesthetic challenges associated with PCR materials. The traditional colour approval process can be lengthy, but Broadway’s on-site colour matching service allows brand owners to review and approve colour plaques on-site, as they’re made.

Colourist and Technical Advisor Ben Wilson explained: “The complexities of colouring PCR are still widely misunderstood. There’s little value in approving a colour sample plaque unless it’s moulded using the same PCR which will be used in the customer’s production run. Any tint in the base material will affect the colour a masterbatch will achieve in the finished article. With our match-on-site service, a customer can provide a sample of their PCR moulding material, we’ll then formulate a colour to give the correct end result when used specifically in that material.

“Switching from virgin to PCR, or increasing the PCR loading will almost always require a change in the masterbatch formulation to counteract the tint of the recycled base polymer. Given the batch-to-batch variances in PCR, this process may need to be repeated for subsequent production runs.

“When brand owners visit us to approve their matches, we can show firsthand how different PCR loadings will alter the colour of their moulding, and to what extent we can counteract this with colour formulations. This enables them to make informed decisions when balancing sustainability and aesthetics. We’ve hosted many brand owners, providing them with valuable insights into colouring PCR while enabling them to approve several new colours in just a few hours. They leave with confidence, having directly overseen the process.”

Broadway’s other solutions for PCR

• Odour neutraliser – PCR materials may carry unpleasant odours, but Broadway offers odour-neutralising additives that can be added to colour formulations to reduce unwanted smells
• PCR carrier masterbatch – For brands claiming “Made from 100% recycled plastic,” it’s important to ensure both their base polymer and masterbatch carrier resin are recycled. Adding a virgin carrier resin can introduce up to 4% virgin plastic into the final product. Broadway’s PCR carrier masterbatches ensure the final component contains no virgin polymer.
• Tint shift – Natural PCR mouldings often have a ‘muddy’ tint. Adding a subtle tint masterbatch can improve the visual appeal by shifting the colour towards a greener or bluer hue.
• Fibre effects and bio-fillers – Some brands note that the addition of PCR material doesn’t alter the appearance of their product enough. These solutions can be used to differentiate product lines containing PCR – offering consumers a clear visual cue to the inclusion of recycled materials.

Broadway’s expertise in PCR colouring is trusted by multinational consumer goods companies and plastic moulders across the UK and Europe. They help businesses achieve both aesthetic excellence and environmental responsibility. For expert advice on colouring PCR or a FREE custom colour match, contact Broadway today.

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