Open Access

REVIEW

Life Cycle-Based Sustainability Assessment and Circularity Mapping for Packaging Materials: Integrating Artificial Intelligence

Ragava Raja R^1,2,*, Girish Khanna R³

1 Department of Printing and Packaging Technology, College of Engineering Guindy, Anna University, Chennai, 600025, India
2 Department of Chemical Engineering, Indian Institute of Technology Madras, Chennai, 600036, India
3 Department of Metallurgical & Materials Engineering, Indian Institute of Technology Madras, Chennai, 600036, India

* Corresponding Author: Ragava Raja R. Email:

Journal on Artificial Intelligence 2025, 7, 301-327. https://doi.org/10.32604/jai.2025.069693

Received 28 June 2025; Accepted 29 August 2025; Issue published 22 September 2025

Abstract

Packaging materials are indispensable in modern industries but also significantly contribute to environmental degradation, resource consumption, and waste generation. This systematic review critically assesses the integration of artificial intelligence (AI), life cycle sustainability assessment (LCSA) following ISO 14040 standards, and circularity mapping to overcome sustainability barriers in packaging. The study identifies environmental, economic, and social hotspots across the life cycle stages of packaging materials by examining real-world case studies such as Coca-Cola’s adoption of recycled PET bottles and Unilever’s commitment to 100% recyclable plastic. AI technologies highlight transformative tools for optimising resource allocation, enhancing waste management, and supporting predictive maintenance in packaging systems. To maximise their impact, circular economy (CE) strategies, including material substitution, reusable packaging, and recycling, are discussed with AI-driven approaches. Policy frameworks like mandatory life cycle reporting and AI-focused capacity-building initiatives drive systemic change. The packaging industry achieves significant sustainability improvements by combining LCSA, CE principles, and AI while fostering economic benefits and social equity. This paper provides a comprehensive foundation for future research and practical applications to transform the packaging sector into a more sustainable and circular system. This review is the first to integrate LCSA, circular economy mapping, and AI applications in sustainable packaging. It highlights practical strategies and identifies research gaps to guide academia, industry, and policymakers toward scalable and intelligent sustainability solutions. Moreover, the review bridges methodological rigour with practical implementation by aligning digital intelligence with material sustainability frameworks, thus forming a multidisciplinary blueprint for a circular future in packaging.

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