Day: July 3, 2024

The NextLooPP initiative’s success and breakthroughs across the Atlantic and an FDA Letter of No Objection to 14 companies bode well for food-grade PP recycling on American shores.

At a Glance

• Research suggests PP residual contamination levels one-tenth of HDPE milk bottles and one-hundredth of PET.
• 2024 trials of recycled PP achieved food-grade purity levels exceeding 95% in packaging applications.
• New performance standards and an automatic sorting technology breakthrough will ease market acceptance.

In May 2023, we published an article in Packaging Digest announcing the NextLooPP initiative’s success with food-grade recycled polypropylene (rPP) in the UK and EU, and our decision to replicate that success in the Americas. Since launching the project in 2020, 53 participants across the plastics supply chain have steadily broken through most of the barriers to producing recycled food-grade polypropylene (FGrPP) from post-consumer waste. We continue to share our science-based findings and expertise with US organizations.

Since that 2023 article, the FDA has given its Letter of No Objection (LNO) to 14 companies in North America, Asia, and Europe to use their recycled resin products for food-contact packaging. Yet, so far, there is no information or publicity on applications of recycled food-grade Polypropylene (PP) resin that are actually being used in food-contact packaging.

It didn’t take long to understand why, given that PP is just embarking on its recyclability journey. If we consider the most widely recycled polymers to date — PET and HDPE — their recycling journey was not an immediate overnight success, either.

I recall when we were first producing food-grade rPET (in the UK) there was considerable reluctance to its use in food-contact packaging, and it required extensive trialing before being adopted for standard production. Now this is an everyday occurrence.

Related:Polypropylene Recycling Venture Sets 2023 Launch in the Americas

PP is currently going through the exact same phase.

Recycled food-grade PP is at the starting gate.

PP accounts for more than 20% of global plastics production and food packaging is one of its primary products. In the USA PP is one of the most converted polymers with a market share of about 20% (in 2018) yet it is also one of the least recycled (3% to 5%) mainly due to its use in non-bottle packaging, such as cups, tubs, and trays.

To understand why recycled food-grade PP resin is still dithering on the sidelines, even with an LNO, we need only check PET and HDPE’s first, tentative recycling steps. The reticence to accept a new resin’s safety is wholly understandable.  It comes from a lack of experience and awareness that this food-grade recycled material can be safely used in consumer food-contact packaging.

The challenge with recycled polypropylene (rPP) is that until now it has not been possible to accurately differentiate between PP packaging that once contained non-food products from those containing food. Consequently, FGrPP has been limited to closed-loop recycling, hand sorting or advanced recycling technology processes based on mass balance (which is not yet recognized as recycling in the EU).

Characterizing residual contamination levels in rPP.

Progress is rapidly catching up, however, through science-based explorations to close the loop on post-consumer food-grade PP. Achieving this has meant methodically addressing every roadblock along the way and diving into the specific sorting and decontamination requirements for the recycling processes for PP. This led to NextLooPP’s investigation to determine the residual contamination levels of post-consumer PP packaging, which up until now, have never been characterized.

A lack of data showing the misuse/mis-selection rate within PP feedstocks prevented any reliable way of defining the residual levels that could potentially migrate into food, and any understanding of which molecules to target via decontamination processes. NextLooPP’s study aimed to identify substances that might cause samples of rPP to be outliers from the expected input stream that could represent challenges to the final safety of the recycled plastics. The key issue was to check whether the substances observed could potentially be genotoxic.

Considerations include the shape of the package.

Although being olefinic, the packaging format of consumer PP packaging reduces the chances of it being in such a consumer-misuse scenario. A large proportion of PET packaging is relatively durable, with a tight closure, making it a container of choice when used for storing hazardous materials. Likewise, HDPE packaging is also in bottle form with a closure meaning it, too, may be used in such a scenario. PP food containers, on the other hand, are less likely to come in bottle form and much more likely to be pots, tubs, or trays with limited closure capability, making them a less likely candidate for consumer misuse.

Characterizing the residues in post-consumer packaging that have been sorted into mono-polymer fractions was done by analyzing and testing multiple batches of food and non-food samples to see what molecules are present and if there are any areas of concern.

To achieve this, our team of scientists worked on 20-tonne (US 22.5-ton) batches of PP bales sourced from a UK-based materials recovery facility (MRF). Using automatic optical sorters to separate color fractions of natural (clear), white, and colored articles, each color fraction was hand-sorted to separate articles from food and non-food applications.
The analytical study involved 700 tests, representing approximately 17,500 different PP packs based on 25 significantly sized flakes per test. This was estimated to be a cross-sectional representation of 7% of the packs from the combination of batches of 260,000 packs.

Following this contamination study, researchers characterized the contamination levels in PP, concluding that they are on the order of 10 times less than that which we expect in HDPE milk bottles; and 100 times less than that expected in PET. This is not surprising given the applications that select PP as the packaging material.

“Finding validated local end-of-life solutions for post-consumer food-grade PP packaging has been the driving force behind NextLooPP’s participants.”

New food-grade resins challenge the status quo.

This study marked a turning point in the NextLooPP project, giving us the confidence to use our PPristine food-grade rPP resins in food-contact packaging.

The performance standards we have now developed will enable us to help organizations reach a high level of technical performance as well as commercial and legal confidence in food-grade rPP. By deploying NextLooPP’s expertise and technical backup, we aim to license the technology to ensure that the resin standards can be fast-tracked into US-produced rPP food-grade packaging.

Finding validated local end-of-life solutions for post-consumer food-grade PP packaging has been the driving force behind NextLooPP’s participants, who continue to produce and trial a range of unique grades of high-quality food-grade recycled PP resins produced using Nextek’s patented PPristine decontamination technology.

Commercialized trials prove the concept.

Eighteen of NextLooPP’s brand and converter participants have now finalized 55 commercialization trials using five PPristine resin grades: Natural food-grade IM, Natural food-grade, White food-grade, Mixed Color food-grade, and non-food grade Mixed Color INRT. The results have been outstanding. For example, trials using 30% of PPristine resins in both extrusion and thermoforming trays achieved product quality comparable with the virgin products with no changes in processing conditions.

Breakthroughs lead the project toward the finish line.

The multi-participant project fine-tunes resin quality standards that are poised to become standard for food-grade recycled PP, and the success continues.

Sorting trials conducted in February by NextLooPP together with Tomra Recycling have confirmed a major breakthrough in the automatic sorting of food-grade PP packaging. The trials combined Tomra’s near-infrared visual spectrometry and GAINnext deep-learning technology. The trials achieved food-grade purity levels exceeding 95% in packaging applications. This is an exciting development and an invaluable boost to the NextLooPP project.

The technology has the potential to be rolled out to all PP packaging sorting facilities and will help produce valuable food-grade, post-consumer recycled PP streams. By providing a sorted food-grade PP PCR stream, GAINnext will enable the NextLooPP decontamination process to be carried out in many more recycling operations globally.

After nearly four years of intense collaboration, the NextLooPP participants are now breaking down the final barriers to producing food-grade recycled PP from post-consumer packaging into new circular economy products, and the initiative is looking forward to launching the NextLooPP Americas project to achieve similar outstanding results.

Source:

https://www.packagingdigest.com/sustainability/food-grade-recycled-polypropylene-is-poised-for-us-intro

Cutting-edge algae-based bioplastics could revolutionize sustainable packaging (and beyond) while meeting consumer and regulatory demands.

At a Glance

• Innate biodegradability and renewability make algae an ideal solution to traditional plastics’ environmental issues.
• Applications include water bottle replacement, food wrappers, drinking straws, and condiment sachets.
• The global bioplastics market is projected to rose from $8.14 billion in 2021 to $18.05 billion by 2027.

Algae, once primarily associated with marine ecosystems, is emerging as a game-changer for sustainable packaging solutions. With the escalating global concern over plastic pollution and the urgent need for eco-friendly alternatives, algae-based packaging has stepped into the limelight — and is not leaving anytime soon.

Below, we’ll explore how this remarkable resource is transforming packaging, why startups are investing heavily in it, and the immense potential algae holds for the future.

The science behind algae-based packaging

Algae refers to a diverse group of aquatic organisms possessing remarkable properties that make them an ideal candidate for sustainable packaging. They can be cultivated rapidly, requiring minimal nutrient input and obtaining energy from sunlight. Algae can thrive in saltwater and even wastewater, reducing the strain on freshwater resources. This adaptability makes them a cleaner alternative to traditional raw materials.

At the heart of algae-based packaging lies its innate biodegradability and renewability. This edge makes it ideal for food packaging and a viable solution to the environmental woes caused by traditional plastics. Algae also absorb atmospheric carbon during growth, further reducing greenhouse gas emissions. Remarkably, they contribute to approximately 70% of the oxygen in the Earth’s atmosphere.

Related:PLA a Prescription for Sustainable Healthcare Packaging

As a packaging material, algae-based polymers offer comparable functionality to traditional plastics while presenting a sustainable end-of-life solution through compostability and biodegradability.

The rise of algae-based packaging

The global algae market is rapidly growing as new uses for algae are continually discovered, generating about $1 billion in sales each year. Here are various innovative applications for algae and seaweed as alternatives to plastic, showcasing their potential to revolutionize packaging and other industries:

• Notpla’s Ooho water pods: Notpla’s Ooho is one of the most prominent examples of algae-based packaging. It’s a seaweed-based edible and biodegradable water pod. It’s a sustainable solution used in conjunction with reusable bottles and has gained significant attention at major events. Over 30,000 Ooho pods were distributed to runners during the 2019 London Marathon, replacing thousands of plastic bottles and substantially reducing plastic waste.

• Evoware’s biodegradable food wrappers: Indonesian startup Evoware has developed biodegradable food wrappers made from seaweed. These wrappers are used for packaging various products, from coffee to cookies to soap. The materials are edible, biodegradable, and home-compostable, ensuring they can safely return to nature without harming wildlife.

• Loliware’s seaweed-based straws: U.S.-based Loliware has created seaweed-based straws designed to replace single-use plastic straws. Unlike paper alternatives, they maintain their structural integrity for up to 24 hours after getting wet. While edible, Loliware straws will naturally degrade in the environment within two months.

• MarinaTex’s fish waste and algae packaging: London-based startup MarinaTex has developed a bioplastic film made from fish waste and red algae. This innovative material is designed for use in packaging and has been awarded the James Dyson Award for its potential to reduce plastic pollution. This bioplastic is stronger than LDPE (low-density polyethylene) and decomposes in four to six weeks under home composting conditions.

• Skipping Rocks Lab’s condiment sachets: Skipping Rocks Lab — the creators of Ooho — has also developed an eco-friendly alternative to single-use plastic packets for condiments and sauces to reduce plastic waste in the food industry. These seaweed sachets biodegrade within six weeks.

The potential for long-term impact

The potential for algae-based packaging to make a significant long-term impact is immense, driven by continuous advancements in research and technology. Ongoing improvements in extraction and processing enhance algae-derived biopolymers’ properties, making them more viable for various applications.

The role of algae in sustainable packaging is poised to expand exponentially as the urgency to combat plastic pollution intensifies. Packaging leaders can harness algae’s inherent properties to spearhead the transition toward a more sustainable and eco-friendly future.

The global bioplastics market, valued at $8.14 billion in 2021, is projected to reach $18.05 billion by 2027, with a CAGR of around 14% from 2022 to 2027. Despite a slight decline in global plastic production, bioplastic demand is rising steadily, driven by technological advancements, increased research and development, and expanding applications.

The rapid growth of the bioplastics market underscores the economic and environmental benefits of sustainable packaging solutions like algae-based materials. Algae require minimal resources to grow and significantly contribute to carbon sequestration. These advantages position algae-based packaging as a scalable, eco-friendly alternative to traditional plastics, addressing environmental concerns and market demands.

Embracing a sustainable future

By embracing algae-based packaging, companies can capitalize on bioplastic technology advancements while meeting consumer and regulatory sustainability demands. Integrating algae-based solutions promises a future where packaging is functional and environmentally responsible.

Incorporating algae-based packaging into your company’s sustainability strategy reduces environmental footprint and positions your brand as a leader in responsible practices. Explore this cutting-edge technology to enhance your product offerings and contribute to a greener future. Your proactive steps today can set the standard for sustainable packaging in the future.

https://www.packagingdigest.com/sustainability/algae-could-revolutionize-sustainable-packaging

Plaintiffs argue companies that make and sell bottled water have violated consumer protection statutes by labeling their bottled water as “natural” when the products allegedly contain microplastics.

Class actions involving bottled water is on the rise as attention focuses on chemicals and plastics in food packaging (in particular, PFAS and microplastics). Following studies in 2018 and 2019 and a fresh February 2024 Consumer Reports study, microplastic litigation should be on every consumer packaged goods manufacturer’s radar. While there is no consensus within the scientific community on harm caused by microplastics, the plaintiffs’ bar has chugged its drink and ran straight to the courthouse.

Plaintiffs across the country, with nearly identical allegations (and for some, the same plaintiff), are not bottling it in anymore. They argue companies that make and sell bottled water have engaged in a host of consumer protection statutory violations by labeling their bottled water as “natural” when the products allegedly contain microplastics. So far this year, we have seen five class actions brought against bottled water manufacturers seeking to certify nationwide and state-specific subclasses.

Without scientific consensus on the impact of microplastics, or guidance from the Environmental Protection Agency or FDA on the presence of microplastics (nor the definition of “natural”), defendants are left to draw analogies to other trending litigation, such as PFAS and glyphosate claims, to challenge these claims. In similar litigation, defendants have found some success in arguing that the FDCA preempts migratory substances like PFAS from disclosure as an ingredient. Likewise, courts have recently found that a “natural” claim could not lead a reasonable customer to believe there are no “accidental or innocuous amounts” of glyphosate in a product. These types of challenges could support dismissal as defendants attempt to put a lid on claims in the bottled-water battle.

Of these five cases, plaintiff Dotson voluntarily dismissed both complaints in April. The other cases are in various stages of motion to dismiss briefing. We’ll watch out for future splashes and keep you updated.

Source:

https://www.packagingdigest.com/sustainability/bottled-water-microplastics-litigation-is-making-a-splash

In partnership with rePurpose Global, the sale of each Chlorophyll Water bottle supports the equivalent recovery of one ocean-bound plastic bottle.

For plastic litter, an ounce of prevention is worth a pound of recovery. That describes the notion of diverting ocean-bound plastic by collecting plastic bottles before they ever reach the water.

The latest bottle brand to wade into the greener waters of preventive sustainability is Chlorophyll Water, a uniquely formulated, green-colored functional water. 

With the brand’s new partnership with rePurpose Global, the sale of each bottle supports the diversion of the the equivalent of one ocean-bound plastic bottle. This ocean-bound plastic is then recycled, reducing the need for virgin plastic.

rePurpose Global is a major Plastic Action Platform that has recovered more than 25 million kilograms/27,558 tons of plastic waste from the environment to date, protecting vulnerable coastal regions across the Americas, Africa, and Asia.

CHLOROPHYLL WATER

Chlorophyll Water has gone deeper into sustainability over the years since the beginning. It debuted in 2019 in biodegradable plastic bottles. In October 2023, it switched to 100% recycled PET bottles. In that same move to rPET, the brand selected CleanFlake label technology from Avery Dennison to optimize the recyclability of the bottles.

Chlorophyll Water was also the first bottled water in the US tested for heavy metals, pesticide residues, and plasticizers to pass stringent Clean Label Project certification.

“Chlorophyll Water is committed to sustainability and using technology to lessen packaging’s environmental impact,” says Matt Levine, founder. “By originally launching in landfill-biodegradable bottles and recently transitioning to 100% recycled plastic bottles, we aim to significantly impact the plastic waste issue and reduce the use of virgin, fossil-fuel-based packaging. Our partnership with rePurpose Global further supports this progressive mission by preventing ocean plastic pollution with every bottle of Chlorophyll Water sold.”

Source:

https://www.packagingdigest.com/beverage-packaging/this-water-bottle-diverts-ocean-bound-plastic