Regulatory challenges and compliance strategies in the packaging industry
Are you designing with
packaging reliability in mind?
Regulatory requirements are evolving, and the packaging industry must navigate a growing array of compliance mandates focused on product safety, environmental sustainability and supply chain transparency. In 2025, manufacturers will face stricter controls, particularly in highly regulated sectors such as food and beverage, medical devices and electronics. Compliance measures such as Extended Producer Responsibility (EPR) programs, toxics-in-packaging laws, and Safe Quality Food (SQF) certifications dictate material choices, production methods, and end-of-life strategies. Adapting to these regulations is crucial for maintaining market access and operational efficiency. Are you prepared to adapt?
In this blog, we’ll explore the key regulatory frameworks shaping the packaging industry, how compliance requirements vary across different sectors, the material selection challenges manufacturers face, and what these regulations mean for OEMs and design engineers. Finally, we’ll highlight how IMI advanced motion control components and solutions can help packaging manufacturers maintain regulatory compliance while optimizing production efficiency.
Extended Producer Responsibility (EPR): Shaping the future of sustainable packaging
As global regulations tighten and consumer demand for sustainability grows, EPR programs are reshaping the packaging industry. These policies place the financial and operational burden of recycling and waste management on producers, driving innovation in eco-friendly materials and circular economy solutions.
As of 2024, seven U.S. states have active EPR or similar packaging laws: California, Colorado, Maine, Oregon, New Jersey, Minnesota and Washington. Each state has its own version of packaging legislation, but most laws focus on reducing waste, encouraging recycling and ensuring that producers are responsible for the entire lifetime of their packaging materials.
For packaging companies, understanding and adapting to EPR regulations is no longer optional—it’s essential for compliance, brand reputation and long-term success.
Main challenges packaging companies need to overcome
Each industry faces unique challenges shaped by product safety requirements, environmental regulations and consumer expectations. As compliance requirements become more stringent across different sectors, manufacturers, OEMs and design engineers must adapt their packaging strategies to meet industry-specific mandates while maintaining efficiency and sustainability. Here are some examples.
Eliminating harmful substances
With growing concerns over hazardous materials in packaging, new legislation is tightening restrictions on the use of harmful substances like heavy metals and PFAS. These laws aim to protect consumers, reduce environmental impact and push companies toward safer, sustainable packaging solutions. Staying compliant isn’t just about avoiding penalties—it’s about future-proofing your business in a rapidly evolving regulatory landscape.
Food and beverage safety standards, migration limits and recyclability
The U.S. Food and Drug Administration (FDA) regulates substances that come into contact with food to verify they do not pose harm to consumers and also assesses the migration of substances from packaging materials into food validating any transfer occurs at safe levels. In the fresh food sector, sustainable packaging must be customized based on the type of produce to support safety and reduce waste. The FDA also provides guidance on the use of recycled plastics in food packaging, emphasizing the importance of verifying that recycled materials meet safety standards.
Medical devices sterility, traceability and regulatory approvals
Medical device packaging regulations in the U.S. are stringent, which is understandable due to their critical role in maintaining patient health and safety.
The FDA’s Center for Devices and Radiological Health (CDRH) enforces comprehensive standards that all device manufacturers, repackagers, and importers must comply with. FDA regulations encompass all aspects of medical device packaging, such as labeling, sterilization and material selection. Adhering to these requirements is essential throughout the supply chain and manufacturing processes to uphold compliance and maintain product integrity.
Electronics e-Waste Laws, Material Restrictions (RoHS, REACH)
The Restriction of Hazardous Substances (RoHS) Directive restricts the use of specific hazardous materials, such as lead, mercury, cadmium and hexavalent chromium, in electrical and electronic equipment. The Registration, Evaluation, Authorization, and Restriction of Chemicals (REACH) Regulation addresses the production and use of chemical substances and their potential impacts on human health and the environment.
Beyond the box: Building quality into every package
Meticulous compliance and effective quality control in packaging operations are the foundation of product integrity, brand reputation and consumer safety. While speed and efficiency drive production targets, maintaining rigorous quality standards throughout the packaging process ensures consistent product quality, reduces waste and prevents costly recalls. Modern quality control procedures combine time-tested inspection methods with advanced automation to create a robust defense against defects and contamination. What to keep in mind:
1.
The right packaging materials
Selecting the right packaging materials requires balancing sustainability, durability, and regulatory demands. Extended Producer Responsibility (EPR) programs push for recyclability, yet packaging must still offer barrier protection and structural integrity. Lightweight, recyclable materials may reduce waste but can lack the strength needed for food, medical, or electronic packaging, requiring manufacturers to explore bio-based, compostable, or reusable solutions. Beyond recyclability, chemical safety regulations like REACH and RoHS restrict hazardous substances such as lead, phthalates, and PFAS. Companies must also ensure traceability, tracking material origins and compliance certifications to meet transparency requirements. Adapting to these evolving regulations is key to avoiding risks while maintaining performance, cost-efficiency, and sustainability.
2.
The hidden costs of non-compliance
Failing to meet regulatory standards comes with more than just financial penalties—it can disrupt operations, delay production, and damage brand reputation. Non-compliant systems often require extensive retesting and re-certification, leading to costly time losses and manufacturing setbacks. Perhaps most damaging, failure to comply with safety and environmental regulations can erode customer trust and invite regulatory scrutiny, making it harder to maintain a competitive edge in the market.
3.
How compliance impacts design and manufacturing
Regulatory compliance is not just a box to check—it fundamentally shapes how products are designed and manufactured. OEMs and engineers must integrate compliance at the earliest stages of design, selecting approved materials that meet safety, environmental and performance standards. Keeping these factors in mind prevents costly redesigns, testing failures and production delays. Beyond material selection, packaging must be designed to align with industry-specific regulations, addressing factors like chemical safety, recyclability and labeling accuracy from the start. Compliance also requires adjustments in manufacturing processes and supply chain management.
Collaborating with experts enables access to components, solutions and technical support that helps prioritize compliance and sets every project on the way to success.
Future-proof your packaging line with precision-engineered solutions
IMI is a global leader in motion and fluid control technologies, delivering innovative solutions that drive speed, efficiency, reliability and sustainability across a wide range of industries.
IMI advanced motion control components play a crucial role in maintaining precision and consistency in highly regulated packaging environments such as food and beverage, medical devices, and electronics. With precise control over packaging processes, IMI solutions help OEMs and manufacturers meet strict safety, quality and material handling standards, minimizing variability and ensuring every product meets compliance requirements. Here is how we do it:
IMI Norgren VS Series Valve Manifolds for packaging
Components like VS Series Valve Manifolds for packaging are essential for optimizing high-speed machinery and customizing packaging equipment for various stages. They integrate seamlessly into packaging systems, ensuring reliability at increased speeds while adapting to changing production needs.
Valve Manifolds allow for easy expansion, enabling systems to accommodate complex configurations without major alterations to the core design. Built for high-speed operations, VS Series manifolds enable seamless integration into packaging lines, support increased throughput and enhance system reliability at higher operating speeds, optimizing scalability and efficiency.
IMI Bimba TA Series NFPA cylinders
Heavy-duty, precision-machined TA Series NFPA cylinders have a self-alignment feature with a floating rod bushing that allows for 0.002" movement. This design ensures at least 25% longer life than a fixed rod brushing design. With reduced friction, these customizable cylinders reduce friction for better actuation responsiveness and reliable, consistent performance in any application.
IMI Norgren Excelon® Plus
Excelon® Plus Air Preparation units offer high flow capacity and efficient contaminant removal, enhancing system longevity while maintaining optimal air pressure in pneumatic systems, even under demanding conditions. Featuring a durable die-cast metal construction and corrosion-resistant coating, these units are designed to be both compact and robust.
