INEOS Styrolution has recently achieved a significant milestone in the sustainability landscape with the successful completion of a project that mechanically recycles polystyrene into yoghurt cups. These innovative products are poised to reach Lidl supermarket shelves in early 2024, marking a critical step in addressing the growing concerns around packaging waste and material recycling.
The company’s advanced purification technology, registered as a novel process in accordance with EU directive 2022/1616, is a game changer in the recycling of food-grade materials. Traditionally, such high-quality recyclates were primarily restricted to PET bottle recycling. INEOS Styrolution’s method incorporates extensive steps, including deep near-infrared (NIR) sorting, object recognition, hot washing, flake sorting, melt filtration, and pelletizing, ensuring that the resulting material meets stringent safety standards for food contact.
Remarkably, the recycled polystyrene exhibits physical properties on par with those of conventionally produced polystyrene, a testament to the rigor of the quality controls and detailed analyses conducted, including an assessment by the European Food Safety Authority (EFSA). The environmental benefits of these recycled yoghurt cups are significant, with estimates suggesting a markedly lower carbon footprint compared to traditional polystyrene products.
In spring 2024, the dairy manufacturer Unternehmensgruppe Theo Müller collaborated with INEOS Styrolution to conduct a consumer test, receiving overwhelmingly positive feedback. An impressive 90% of testers expressed willingness to purchase yoghurt cups made from recycled polystyrene, even acknowledging that these cups might be available in various colours beyond the conventional white.
Dr. Frank Eisenträger, ECO & Market Development Manager at INEOS Styrolution, articulated the importance of this development, stating, “Polystyrene has arrived in the champions league of recycled food contact materials.” This innovation enables producers to comply with the new EU Packaging and Packaging Waste Regulation (PPWR), a crucial step towards sustainable packaging practices.
Furthermore, Lena Lembach, Senior Packaging Development Manager at Unternehmensgruppe Theo Müller, emphasized the collaborative approach to achieving circularity within the polystyrene market and reaching CO2 footprint reduction goals.
This latest advancement follows the establishment of an advanced mechanical recycling facility in collaboration with TOMRA and EGN Entsorgungsgesellschaft Niederrhein, aimed at converting 40,000 tons of post-consumer polystyrene into recycled material annually. Additionally, previous initiatives have included the development of a form-fill-seal yoghurt pot comprising 98.5% polystyrene, which not only streamlines the recycling process but has also garnered accolades in the sustainability sector.
As INEOS Styrolution leads the way in turning challenges into opportunities, the introduction of recycled polystyrene yoghurt cups represents a significant advancement in sustainable packaging solutions, paving the way for broader adoption and innovation in the food packaging industry.
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