To reuse or not to reuse: That is the question. Environmental trade-offs between reusable and recyclable packaging for large appliances

This study aims to answer the Hamlet dilemma of packaging for large home appliances, i.e., to reuse or not to reuse, by evaluating the environmental trade-offs between recyclable and reusable packaging for large home appliances through a comparative life cycle assessment (LCA). Using washing machines as a case study, the research analyses four realistic distribution scenarios between Italy and France to determine under what conditions reusable packaging is environmentally preferable to recyclable packaging and vice versa. The LCA considers production, use, and end-of-life phases, with Climate Change as the reference impact category. Results show that recyclable packaging generally has a lower environmental impact, except for short transport distances (below 425 km for road transport and below 750 km for intermodal transport). A sensitivity analysis shows that these distance values may vary considerably depending on the impact category considered. Furthermore, additional sensitivity analyses on the number of reuse cycles and on the weight of the reusable packaging solution reveal that reusable packaging can be competitive with the recyclable option if used over 45–70 times or if its weight is reduced to approximately 9–11 kg, depending on the scenario. The study contributes to the literature in multiple ways. Firstly, it confirms that the environmental performance of packaging options depends on numerous factors and encourages data-driven decision-making to identify optimal solutions for large appliances. This outcome is demonstrated by applying a breakeven point analysis to the large appliances sector for the first time, supported by an extensive sensitivity analysis on the model parameters. Moreover, the study proposes a set of suggestions for policymakers, manufacturers, and retailers. Finally, the results of this study are highly sensitive to the choice of transport modes; therefore, these should be carefully evaluated, particularly in intermodal scenarios where multiple routing combinations are possible.