The plastics industry is entering a decisive phase in its transition toward a circular economy. For packaging convertors and buyers, incorporating recycled material is no longer just a voluntary sustainability or eco-design strategy; it is now a regulatory requirement shaping industrial planning, material selection, and commercial product viability.
However, in the food packaging sector, this transition faces a critical bottleneck: the limited availability of food-grade post-consumer recycled resin (food-grade PCR) in polypropylene (PP) and polyethylene (PE).
Why does this mismatch exist, and how will it impact the future of packaging? We analyze it below.
The Mismatch Between PPWR Regulations and Market Reality
The new European Packaging and Packaging Waste Regulation (PPWR) sets clear, unavoidable targets for 2030:
- Contact-sensitive PET packaging: Must contain at least 30% recycled content.
- Other plastic packaging (including PP and PE): Must reach a minimum of 10% recycled material.
The critical issue is not how much PCR resin the global market will need, but what percentage of it will meet strict food safety regulations. Food-contact applications demand purity and decontamination levels far superior to any other industrial use.
Why Is PET Progressing Quickly While Polyolefins (PP/PE) Fall Behind?
PET (widely used in water and soda bottles) holds a clear advantage in the circular economy race thanks to three main factors:
- Highly homogeneous waste streams.
- Well-established deposit-return and collection systems.
- Mature EFSA (European Food Safety Authority) evaluations for mechanical recycling.
In contrast, PP and PE (polyolefin) streams present significantly greater fundamental complexity. Waste from these materials comes from highly heterogeneous formats:
- Rigid containers and closures.
- Films and multilayer structures.
- Flexible packaging containing a wide variety of inks, adhesives, and additives.
The Heterogeneity Problem: This mix hinders automated sorting, degrades the consistency of the recycled material stream, and weakens the deep decontamination required for food-contact use.
From Mechanical to Molecular Recycling: A Technical Necessity
Mechanical recycling works exceptionally well for removing visible contaminants and is fully suitable for non-food applications. However, it often falls short when it comes to removing absorbed organic compounds or complex additives that could migrate into food.
As a result, molecular (or chemical) recycling has evolved from an experimental concept into a structural technical necessity. This technology allows producers to:
- Break down the polymer at the molecular level to return to its basic building blocks.
- Completely eliminate the full spectrum of contaminants and additives.
- Produce virgin-like resin with precise composition control, making it safe and compliant for direct food contact.
From Mechanical to Molecular Recycling: A Technical Necessity
Mechanical recycling works exceptionally well for removing visible contaminants and is fully suitable for non-food applications. However, it often falls short when it comes to removing absorbed organic compounds or complex additives that could migrate into food.
As a result, molecular (or chemical) recycling has evolved from an experimental concept into a structural technical necessity. This technology allows producers to:
- Break down the polymer at the molecular level to return to its basic building blocks.
- Completely eliminate the full spectrum of contaminants and additives.
- Produce virgin-like resin with precise composition control, making it safe and compliant for direct food contact.
Looking Ahead to 2030: An Unavoidable Industrial Challenge
Everyday applications such as fresh produce tubs, yogurt cups, or deli trays will urgently require a stable, commercial supply of food-grade recycled PP and PE.
Upgrading sorting and washing plants across Spain and Europe will help improve quality, but it will not bridge the gap on its own. The sector’s true challenge lies in accelerating the industrial scaling of molecular recycling to keep pace with legislation that, as of today, is advancing faster than actual supply capacity.
At Coverpan, we closely monitor this transition, driving the development of packaging solutions that stay ahead of PPWR requirements while guaranteeing maximum food safety and sustainability in every product.
