The companies say that PET shelf-ready packaging, which is used in UK supermarkets to transport products, is usually downcycled into non-food applications. The new ‘tray to tray’ initiative will involve Faerch collecting secondary PET and using its advanced recycling process to make new primary food contact packaging, including pots, tubs, and trays.
Tesco adds that packaging for its own brand cut fruit, selected yoghurts, and meat will contain 30% rPET originating in Tesco stores. It will therefore require all Tesco own brands and branded suppliers to use food contact approved PET for shelf-ready packaging.
In addition, Tesco claims this initiative will provide a solution to the shortfall in recycled PET availability due to increasing demand for PET bottle flakes.
William Guest, sustainable packaging manager at Tesco, comments: “Wherever we can, we remove or reduce packaging but where it is needed we want to improve circularity to make our packaging as sustainable as possible.
“One way we can do that is by ensuring packaging that meets food contact requirements remains within the food packaging sector, being recycled back into food contact packaging.
“This collaboration with Faerch will ensure that each year 2,000 tonnes of PET is recycled to make new Tesco packaging that otherwise would have been downcycled into non-food applications.”
According to Matt Tollman, group strategic sales director at Faerch: “This is a perfect example of how collaboration between packaging manufacturers, retailers and their suppliers can deliver lasting change and material circularity.
“The ‘Tray 2 Tray by Faerch’ project demonstrates that PET packaging can be recovered and recycled at an industrial level and made back into food grade pots and trays.”
The new initiative is part of Tesco’s strategy for reducing plastic waste, first launched in 2019, which involves removing packaging where possible, reducing packaging where it cannot be removed, increasing reuse, and recycling what is left after these options. The strategy has allegedly removed a billion pieces of plastic from Tesco’s UK business operations, and the supermarket chain is aiming to remove a further half a billion in 2021.
Previous initiatives announced by Tesco include a trial for recycling items such as laminated pet food pouches, sweet wrappers, and crisp packets returned to stores by consumers into chemical feedstock and plastic packaging for cheeses launched in 2020, which is made from recycled soft, flexible plastic packaging that can also be continuously recycled into safe, food-grade packaging. The ‘tray to tray’ and other initiatives also complement Tesco’s launch of Loop in September 2021, which allows customers to buy products in packaging that can be returned to stores for cleaning, refill and reuse.
The bottles will be the first to use rPET from the Esterform Packaging facility, based in North Yorkshire. According to Britvic, the move will save 1,354 tonnes of virgin plastic per year.
Mark Tyne, Esterform’s managing director, said: “Our £20m project to produce 42,000 tonnes of recycled food grade PET could not have got off the ground without Britvic’s support and we look forward to working together to rollout recycled PET usage across Britvic’s portfolio.”
Sarah Webster, director of sustainable business at Britvic, added: “We are extremely proud and excited to see the first use of Esterpet in our iconic brands as they make the move to 100% rPET.
“It’s a fantastic example of the progress made in the facility with Britvic’s investment support and the first in a series of changes using Esterpet packaging as we continue our journey to fulfil our rPET commitment.”
The move is in addition to the 1,900 tonnes already saved by Ballygowan Mineral Water and Fruit Shoot Hydro switching to rPET bottles. Last year, Britvic set a target for all of its UK plastic bottles to be made from 100% recycled plastic by the end of 2022.
PET converter Esterform Packaging has supplied Britvic for over 15 years.
The BIO radishes are marketed in a 100% R-PET container, designed with a minimum micron size, which can be recycled for reuse. In addition to innovating with the material used, Agromediterránea has picked a format that had so far never been used for radishes: a 200-gram cup with a lid - instead of the usual bag or flowpack - which keeps the product fresh for longer and facilitates its consumption.
“We continue to innovate to always find the best ways to bring our products directly from the field to our customers. We are constantly testing various alternatives and we are able to offer a wide range of more sustainable options adapted to current consumer demands,” says Jesús Gómez, general director of Agromediterránea.
Through its alliance with Prevented Ocean Plastic, the company is contributing to the circular economy and helping avoid the environmental pollution of the oceans. The initiative - promoted by the packaging manufacturer Grupo Gullin - is also having a positive economic impact in those areas where plastic is collected, since local communities are directly involved in a process certified by the independent organization OceanCycle.
The introduction of POP certified plastic is expanding the range of sustainable packaging options offered by Agromediterránea. It already has products with zero plastic and 100% recyclable options, such as kraft cardboard banding for zucchini, or cellulose trays for corn.
Spanish beverage company Estrella Damm has partnered with US-based packaging solution provider Graphic Packaging International (GPI) to introduce paperboard alternatives for its multipacks.
The beer company has launched a rounded-corner pack designed and developed by GPI. Formats for 6, 12 and 24-packs have so far been launched.
The packaging wraps tightly around the cans, protecting them from damage at all points in the supply chain.
This move is expected to save 99t of plastic a year.
Graphic Packaging innovation and design manager Ana González said: “This is the first structure of its kind in the beverage market. We have worked closely with Estrella Damm’s team to ensure that our plastic replacement solution is innovative and strengthens the brand.
“The elevated shelf appeal of this solution is the culmination of a long and successful collaboration between Graphic Packaging and Estrella Damm.”
GPI has installed the first of two QuikFlex machines to meet production and market needs.
Last month, GPI launched a recyclable paperboard packaging solution to help beverage brands meet their plastic reduction goals.
The Cap-It clip is designed for multipack polyethylene terephthalate (PET) or recycled (rPET) bottles. Made of renewable materials, it serves as a sustainable alternative to traditional shrink wrap packaging.
In October 2019, GPI launched KeelClip, a paperboard solution for various can styles and sizes and multiple product configurations.
To promote the solution, the company partnered with Belgian beverage firm Anheuser Busch InBev (AB InBev), who started using it for their brands last year.
The new Schick Xtreme 3 Eco Glide razor is “the first and only disposable razor made from recycled plastic that’s also fully recyclable,” according to manufacturer Schick. “This innovative razor features unique Xtreme 3 flexible blade technology to adapt to and hug contours, plus 50 percent more aloe lubricant to settle sensitive skin. Its lightweight, easily portable handle has an ergonomic grip (made without rubber for easier recycling) that allows for superb control.”
The Xtreme 3 Eco Glide razor isn’t a fully new product per se, rather it is a differently manufactured version of Schick’s existing Xtreme 3 Disposable product line with a handle that uses recycled (and recyclable) polypropylene and thermoplastic elsastomer, rather than virgin.
The package for this greener version of the disposable razor also represents a departure from the original and concurrently existing Schick Xtreme 3 Disposable package, which has for some time consisted of a thermoformed biaxially oriented polypropylene (BOPP) tray with film lidding. Instead, the new Schick Xtreme Eco Glide variety is packaged in a kraft-style paperboard carton. This Schick Xtreme Eco Glide carton has no internal pieces, unlike the existing Schick Xtreme 3 Disposable thermoformed tray which uses with insert card. The carton is printed flexographically.
“The facing is approximately the same size, but the shape is obviously very different since the pack structure has changed,” says Natalya Utesheva, Senior Brand Manager at Schick.
This printed kraft paperboard carton should be recyclable in most municipalities, though the company can’t claim 100% in the case that certain recycling centers may not be able to handle impurities such as inks and glues. The new cartons are received at the Mexico City packaging facility as finished cartons, meaning they are printed, cut, creased, formed, and glued when they arrive. There, they are manually loaded with product and secured.
Notably, the original Schick Xtreme 3 Disposable razor handle got a sustainability profile improvement of its own by switching from virgin PETG, to 100% rPET post-consumer recycled content.
Following up on the previous blog, we want to share with you 5 nationally and internationally brands that adopted 100% recycling or 100% recycled packaging in 2020.
The new Dettol Liquid handwash Black is made with 100 percent Post-Consumer Resin (PCR).
ALPLA switched its PET Recycling Team plants in Wöllersdorf, Austria, and Radomsko, Poland, to a mix of electricity from renewable sources in order to produce carbon-neutral rPET (= recycled polyethylene terephthalate). ‘This step has already had a big impact on the carbon footprint of our food-grade regranulate – according to the calculations, emissions are cut by up to 90 per cent compared with virgin material. The feedback from the market regarding this further development has been very good,’ explains Georg Lässer, Head of Recycling at ALPLA.
The company is now offering its customers carbon-neutral rPET based on the purchase of certificates. The remaining, unavoidable emissions relating, for example, to delivery of the input material to the plants, are then offset with carbon certificates. ‘The world’s first carbon-neutral regranulate can make a significant contribution to climate protection and highlight the value of used plastics,’ says Lässer.
Carefully selected projects with a social background
ALPLA has selected specific projects in cooperation with the climate neutrality alliance Klimaneutralitätsbündnis 2025 and the social enterprise Helioz. A reforestation project in Nicaragua is being supported. In China, traditional coal-fired stoves are being replaced with ovens run on biomass. These not only vastly reduce emissions, but also prevent the health implications caused by harmful exhaust air. In Ethiopia, 5,000 household packages (modern stoves, vegetable seeds, seedlings, training) are being financed. In regions in Asia and Africa, ALPLA is supporting the organisation Helioz, which provides solar devices that monitor water disinfection using PET bottles.
Recycling for climate protection
Based on life cycle assessments, packaging types containing a high proportion of recycled material have the least impact on the climate. With the world’s first carbon-neutral rPET, ALPLA is helping its customers to achieve their sustainability goals. ‘We are once again demonstrating that close collaboration between packaging developers, packaging manufacturers and recycling experts can lead to solutions which set an example for the industry as a whole,’ Lässer concludes affirmatively.
Coca-Cola in Western Europe today takes another important step on its journey to eliminating new virgin oil-based plastic as Coca-Cola in the Netherlands and Coca-Cola in Norway announce their transition to plastic bottles made from 100% recycled plastic (rPET). Following the announcement (December 2019) that Coca-Cola in Sweden would become the first market to switch to 100% rPET, Coca-Cola in the Netherlands has announced that from October 2020 it will transition all its locally produced small plastic bottles to 100% rPET, including iconic brands such as Coca-Cola, Sprite and Fanta. Large plastic bottles will follow in 2021, making it the second market to transition its locally produced portfolio to 100% rPET. The switch to 100% rPET in the Netherlands will eliminate the use of more than 10,000 tonnes of new virgin oil-based plastic, amounting to a 21% reduction in the carbon footprint of its plastic bottles per year compared to the rPET level before the transition, when the portfolio in the Netherlands already consisted of more than 50% recycled PET. Additionally, during the first half of 2021, Coca-Cola in Norway will transition to 100% rPET for all plastic bottles that it produces locally. This transition will remove around 4,300 tonnes of new virgin oil-based plastic a year, and will deliver a 28% reduction in the carbon footprint of its plastic bottles per year compared with the rPET level before the switch when the portfolio in Norway was approximately 25% rPET. Both Coca-Cola in the Netherlands and Coca-Cola in Norway will be the first companies in their respective countries to move their entire portfolio of locally produced plastic bottles to 100% rPET. This move supports Coca-Cola’s ambition in Western Europe to accelerate towards the use of 100% rPET and the elimination of new virgin oil-based PET in all of its bottles within the next decade.
News:“The launch of this new product responds to Nestlé Waters’ commitment that all mineral water bottles, which are already 100% recyclable, will contain an increasing percentage of recycled plastic”, said Philippe de Maillardoz, director of Nestlé Waters Spain. This is the first bottle made of 100% recycled PET plastic that we launched in the Spanish market. In the coming months, we will continue to expand the use of recycled plastic in other key formats in our portfolio,” he added. Committed to sustainability This new format forms part of Nestlé’s global drive to increase the use of alternative packaging materials, as well as specific commitments made by Nestlé Waters regarding environmental sustainability and plastic packaging. According to the press note, Nestlé Waters Spain has reduced the amount of plastic used in water bottles by an average of 20% since 2010. In addition, it is working to have all its bottles, which are already 100% recyclable, contain at least 50% recycled plastic by 2022 in the country.