Recycling Versus Landfilling of Plastic Packaging: Comparative Life Cycle Energy Implications Under Circular Economy Conditions

Plastic packaging is indispensable in modern food and beverage supply chains. However, its production and end-of-life management require substantial primary energy inputs. Improving the energy efficiency of packaging systems is therefore a key objective of circular economy strategies. This study applies Life Cycle Assessment (LCA) to evaluate the cumulative energy demand (CED) of a beverage packaging system comprising polyethylene terephthalate (PET) bottles, recycled polyethylene terephthalate (rPET) bottles, high-density polyethylene (HDPE) caps, and polypropylene (PP) labels under two end-of-life scenarios: recycling and landfilling. The assessment was performed using Polish production and waste-management conditions (2022–2024). A functional unit of 100,000 complete 1 L beverage packages was adopted, and the life cycle inventory combined primary industrial data with background datasets from the ecoinvent database. Recycling scenarios were modelled using a substitution-based allocation (system expansion) approach. The results indicate that non-renewable energy accounted for approximately 88–97% of the total cumulative energy demand of the analysed packaging components. Among the investigated materials, PP labels exhibited the highest component-specific cumulative energy demand, whereas rPET bottles showed the lowest values, corresponding to an approximately 13% lower energy demand than conventional PET bottles under the adopted modelling assumptions. Recycling consistently outperformed landfilling by reducing cumulative primary energy demand across all analysed impact categories, with the greatest energy-saving potential observed for PP labels. Negative CED values obtained for selected recycling scenarios represent avoided primary energy resulting from virgin material substitution rather than physically negative energy consumption. The findings demonstrate that component-level LCA provides a robust basis for identifying energy hotspots within plastic packaging systems and supports evidence-based decisions regarding eco-design, material selection, and recycling strategies. Although the absolute CED values are specific to Polish production and recycling conditions, the overall results confirm that material recycling is a more energy-efficient end-of-life strategy than landfilling and contributes to the development of more sustainable circular packaging systems.