Why rPET Matters for Food Packaging

Recycled Polyethylene terephthalate has become synonymous with this most popular of applications.

Recycled polyethylene terephthalate (rPET) is making big waves in the food packaging industry as companies and consumers alike push for more eco-friendly solutions. With advancements in technology, new regulations, and a growing focus on sustainability, rPET is becoming a popular choice for food packaging. Here’s a closer look at what’s new and exciting in this space.

One of the biggest challenges with using rPET in food packaging has been ensuring its safety for food contact. Thanks to advancements in decontamination technology, rPET can now be cleaned to incredibly high standards. These processes ensure that any potentially harmful substances from the recycling process are effectively removed, making rPET safe to use for food and beverages, meeting strict safety standards set by agencies including the U.S. Food and Drug Administration (FDA) and the European Food Safety Authority (EFSA).

Governments and companies around the world are stepping up to cut down on plastic waste, and rPET is a big part of that plan. In the European Union, for example, regulations now require that PET bottles contain at least 25% recycled content by 2025, and that number will jump to 30% by 2030 [1,2]. These rules are prompting manufacturers to find ways to incorporate more rPET into their packaging. At the same time, many big brands are setting their own ambitious sustainability goals. Coca-Cola [3], PepsiCo [4], and Nestlé [5] are aiming to use 50% or even 100% recycled PET in their bottles and packaging. Coca-Cola has even rolled out 100% rPET bottles in certain markets, which is a great example of how companies are making good on their sustainability promises.

For rPET to be effective, high-quality starting materials are needed, which means improving both the collection and sorting of PET waste. This is where new technology comes into play. Advanced sorting systems powered by artificial intelligence (AI) are now helping recycling facilities better identify and separate PET from other types of waste. Deposit return schemes (DRS) and extended producer responsibility (EPR) programs are popping up in more regions, encouraging people to return their used PET bottles, ensuring a steady supply of materials for recycling, and creating a more efficient loop for producing food-grade rPET [6].

Mechanically sorted, washed, and shredded rPET can gain further value with reactive masterbatch technology to both repair and upcycle feedstocks. Reactive extrusion with thermally active masterbatches rebuilds rPET, improving the manufacturing efficiency of sheets for packaging [7].

One of the most exciting trends in rPET packaging is the focus on designs that enable easier recycling. Simpler packaging is free of tricky components e.g. non-recyclable labels or mixed materials that complicate the recycling process. By focusing on single-material PET designs and eliminating unnecessary extras, companies are helping to improve the recyclability of their products, leading to more efficient recycling and higher-quality rPET feedstocks.

Consumer are more environmentally conscious than ever, and many are purposefully choosing products that come in sustainable packaging. This shift in buyer behavior is pushing brands to adopt rPET in their food packaging. More shoppers are looking for packaging that’s not only functional but also reduces their environmental impact, and companies are responding by incorporating more, and higher levels of, recycled content.

Let’s wrap by acknowledging that rPET has become the go-to material for food packaging as companies and regulators look for ways to reduce plastic waste and create more sustainable packaging solutions. Thanks to better cleaning technologies, smarter sorting systems, novel processing additives, supportive regulations, and growing consumer demand, rPET is poised to expand its role in the future of safer, cleaner, and greener food packaging.

Want to learn more about rPET recycling, including the use of reactive masterbatches to improve processing/properties? Reach out today for an initial consultation.