Earlier in 2025, Packaging South Asia visited the Mumbai-headquartered EPL’s tube manufacturing site in Vapi. A global leader in laminated plastic tubes, providing primarily to the FMCG and pharmaceutical sectors, the company operates 21 manufacturing facilities across 11 countries, with a market presence in over 100 countries. In India, it runs eight plants.
EPL puts strong focus on sustainability, setting a target to achieve net-zero greenhouse gas (GHG) emissions across its value chain by 2050. In an interview with Shardul Sharma, EPL’s Jayesh Boraste, general manager global sustainability and Hariharan K, president – creativity & innovation, discuss the company’s sustainability initiatives, interim milestones, strategic emission reduction roadmap, its phased action plan, and much more.
PSA: How does EPL plan to increase the share of sustainable and recyclable packaging to 100%, and what are the main challenges in this transition?
JB and HK: EPL’s share of sales in the sustainable format of packaging in FY 25 was 33%. So, every 1 in 3 tubes that EPL sells is fully recyclable in the HDPE stream.
The shift to sustainable formats is guided by the development of tube designs that not only fulfill the functional requirements of the product but also align with brand commitments toward sustainable packaging. Building on the progress made in recent years, we anticipate a continued and steady increase in the share of sustainable tube formats in the coming years.
The key challenge anticipated in achieving a full transition to 100% sustainable formats is ensuring that the web structure meets the required barrier performance, particularly for oxygen- or moisture-sensitive formulations. Additionally, overcoming legacy system dependencies and organizational resistance to change remains a consideration in certain applications.
With a commitment to achieve Net Zero by 2050, what interim milestones has EPL set for reducing Scope 1, 2, and 3 emissions?
JB and HK: EPL has established a clear and science-aligned roadmap to achieve net-zero greenhouse gas (GHG) emissions across its value chain and an overall goal of achieving net-zero GHG emissions across Scope 1, 2, and 3 by 2050. In line with global best practices, EPL became a signatory to the Science-Based Targets initiative (SBTi) in August 2021. Our near- and long-term emissions reduction targets were formally validated by SBTi in June 2024.
EPL’s near-term targets (by 2030) include reducing absolute Scope 1 and 2 GHG emissions by 55% from a 2017 baseline as well as absolute Scope 3 GHG emissions from purchased goods and services by 42% from a 2020 baseline. The long-term targets (by 2050) are reducing absolute Scope 1 and 2 emissions by 90% from a 2017 baseline and absolute Scope 3 emissions by 90% from a 2020 baseline.
To support these targets, EPL has defined a phased action plan –
Phase 1, from the year 2021 to 2023, included laying the groundwork. Among other measures, EPL committed to Net Zero by 2050 with SBTi verification; initiated renewable energy integration and energy efficiency improvements; launched internal awareness programs to promote sustainability engagement; and, strengthened stakeholder collaboration and enhanced ESG disclosures.
Phase 2, from 2023–2030, is building on our progress. The steps taken include delivering measurable reductions in Scope 1 and 2 emissions; expanding renewable energy adoption across global operations; increasing the use of sustainable and recyclable packaging materials; and advanced waste management, water recycling, and circular economy initiatives.
Phase 3, from 2030 to 2040, involves scaling up the climate section. The measures include transition of facilities to carbon-neutral operations; scaling water recycling and achieving near-zero waste-to-landfill across sites; and deepening reliance on renewable energy across all manufacturing locations.
Phase 4 from 2040–2050 targets Net Zero. The aim is to realize full Net Zero across operations and supply chain; Lead in circular economy practices with 100% recyclable and bio-based packaging; and build a carbon-neutral supply chain through strategic partnerships and innovation.
Through this phased approach, EPL remains committed to achieving a just, measurable, and science-backed transition to a low-carbon future.
Can you elaborate on the impact of EPL’s shift from aluminum barrier laminate (ABL) to plastic barrier laminate (PBL) tubes on both environmental sustainability and operational efficiency?
JB and HK: EPL’s shift from aluminum barrier laminate (ABL) to plastic barrier laminate (PBL) tubes represents a strategic step toward enhancing both environmental sustainability and operational efficiency.
As far as environment sustainability impact and recyclability, PBL tubes are made entirely from plastic polymers, making them fully recyclable in existing plastic recycling streams, unlike ABL tubes, which contain aluminum layers and are more challenging to recycle.
For material circularity, the transition supports the development of a circular economy by enabling easier reintegration of post-consumer materials into the production cycle. And for achieving reduced carbon footprint, the elimination of aluminum reduces the energy intensity and associated greenhouse gas (GHG) emissions during raw material processing and tube manufacturing.
Operational efficiency impact
By manufacturing simplification, PBL structures streamline the production process, as they eliminate the complexity of bonding dissimilar materials (plastic and aluminum), resulting in better process control and reduced wastage. PBL tubes allow for faster production runs and greater flexibility in design and printing, including the use of high-quality digital and flexographic printing technologies. For regulatory compliance and growing regulatory pressure and customer demand for sustainable packaging, the shift enhances EPL’s market responsiveness and competitiveness. Overall, this transition aligns with EPL’s long-term sustainability vision, while also delivering tangible benefits in production agility, cost-efficiency, and customer value.
How is EPL leveraging partnerships, such as the one with Banyan Nation, to advance circularity in tube packaging?
JB and HK: EPL is advancing circularity by incorporating locally sourced PCR resins (with FDA letters of authorization) into our tube structures at levels of up to 70%. We are collaborating with recyclers to establish pilot projects focused on the collection of used tubes, to reintegrate them into the value chain to further enhance circularity.
EPL’s 2024 sustainability report mentions a 17% reduction in Scope 1 and 2 emissions. What specific energy efficiency and renewable energy measures contributed most to this reduction?
JB and HK: EPL has committed to near-term science-based targets to reduce absolute Scope 1 and 2 greenhouse gas (GHG) emissions by 55% by 2030, compared to a 2017 baseline. Our renewable energy transition began in 2018, with our Germany plant becoming the first to achieve 100% of its energy needs from renewable sources—representing 3% of our global energy consumption at the time. Since then, we have significantly scaled up our renewable energy initiatives. As of today, 25% of EPL’s total energy consumption is derived from renewable sources.
Our key achievements include 100% renewable energy usage in Colombia; 25% of energy from renewables in the USA and Poland; and 100% renewable energy through Energy Attribute Certificates (EACs) for the past two years in China (Jiangsu). In India, our Nalagarh & Manpura – Nalagarh 2 plants in Himachal Pradesh source 90% of their grid electricity from renewable energy. The Assam plant uses 16% renewable energy.
To reduce our Scope 1 emissions, EPL has transitioned from diesel-operated tow trucks to battery-operated alternatives. These batteries are recharged using renewable energy sources, as outlined above in our ongoing renewable energy initiatives. This shift not only lowers direct emissions but also reinforces our commitment to sustainable and clean energy practices across operations. This progress underscores our strong commitment to decarbonization and advancing toward our net-zero goals.
How does EPL’s supplier sustainability code of conduct ensure that environmental and human rights standards are upheld throughout the value chain?
JB and HK: EPL endeavors to work to make its supply chain sustainable. The first step is adopting and integrating corporate social responsibility principles on environment, social, and ethics in its procurement process. In alignment with EPL’s sustainability approach and journey, we have developed a ‘supplier sustainability code of conduct’ to ensure all our suppliers meet basic expectations of doing business while complying with legal requirements, ethical practices, human rights, and environmental management.
It is based on globally recognized and accepted international standards, including the International Labour Organisation, UN Global Compact principles, United Nations’ Business and Human Rights principles and industry best practices. Compliance with the code of conduct is an expectation of doing business with EPL; it defines minimum standards that EPL expects the suppliers and their sub-tier suppliers or sub-contractors (‘the supplier’), to respect and adhere to.
EPL has established a comprehensive approach to sustainable procurement, supported by clearly defined long-term quantitative targets. These targets are tracked and reported annually through the Supply Chain KPI table, along with data assurance at a reasonable level from a third party in the sustainability report.
A few KPI examples are — Percentage of suppliers who have signed the sustainable procurement charter or supplier code of conduct; those who have undergone a sustainability on-site audit; suppliers engaged in capacity-building initiatives; supplier operations covered by human rights risk assessment performed by EPL; and the percentage of buyers across all locations who have received training on sustainable procurement. This structured and data-driven approach reflects EPL’s commitment to embedding environmental and social responsibility across its supply chain.
What role do EPL’s global R&D and innovation centres play in developing new sustainable materials, and how are these integrated into commercial production?
JB and HK: At EPL, our innovation is driven by three factors – technology, evolving market demands and development of environmentally friendly products. We collaborate with our customers to conceive ground-breaking ideas and execute them. We offer unique and specialized eco-friendly product packaging solutions for a range of applications.
Our intellectual property filings in recent years stand as clear evidence of the R&D efforts and sustained focus on advancing sustainability. EPL production capabilities are continuously upgraded to be the best in line with the evolving demands of markets.
With women comprising 29% of EPL’s workforce and an emphasis on diversity, what strategies are in place to further enhance inclusivity, particularly in leadership roles?
JB and HK: EPL is committed to promoting diversity, equity, and inclusion (DEI) across its global operations. With 29% of its workforce comprising women, the company aims to increase this to 32% by 2030 through targeted initiatives in recruitment, leadership development, workplace culture, and accountability. Strategic efforts include encouraging 50% of job applications to come from female candidates, partnering with women-focused recruitment agencies, and offering incentives for employee referrals. While representation varies across regions, EPL outperforms market averages and is dedicated to addressing challenges in attracting female talent, particularly in manufacturing. The company also supports leadership development through diverse conferences and partnerships with women’s empowerment organizations.
What future investments are planned to further support EPL’s goal of integrating advanced smart water and waste management technologies into its global operations?
JB and HK: EPL is committed to driving sustainable operations by integrating advanced smart water and waste management technologies across its global operations. As part of our long-term environmental stewardship strategy, we are undertaking targeted investments in the following key areas:
Digital water management systems – We are deploying real-time water quality and consumption monitoring systems using IoT sensors and automated analytics to track, optimize, and reduce water usage across our plants. A pilot system has already been successfully implemented at our Vasind facility in India.
Closed-loop water recycling – We are expanding our advanced sewage treatment infrastructure to enable water reuse and reduce dependence on freshwater sources. All EPL plants in India are equipped with STPs, and our Nalagarh (Himachal Pradesh) and Assam plants have integrated rainwater harvesting systems.
Waste-to-resource circularity – We are scaling up circular economy initiatives through improved waste segregation, material recovery, and collaboration with recycling partners. Our Wada (India) and Guangzhou (China) plants have installed post-industrial recycling technologies that convert plastic waste into granules, which are then repurposed for manufacturing liners, pallets, and collection sheets — helping reduce virgin plastic usage.
Zero waste to landfill – Through sustained efforts to reduce, reuse, and recycle, our plants in Wada and Vasind (India), as well as Nalagarh (Himachal Pradesh), have achieved Zero Waste to Landfill certification. We are actively working to replicate this success across our global facilities.
Global standardization and capability building – To ensure consistent implementation of smart water and waste practices, we are establishing global standards and delivering targeted training programs to empower local teams across regions. These strategic investments are aligned with EPL’s Science Based Targets and ESG roadmap, reinforcing our commitment to resource efficiency, regulatory compliance, and long-term sustainable value creation for all stakeholders.
