The global plastic industry is undergoing significant transformations as virgin plastic production surpasses demand and utilization rates hover around 70%. In the coming years, experts predict downward pressure on virgin plastic prices. Concurrently, tariffs on U.S. plastics trade are disrupting domestic supply chains, adding to market volatility. To address these challenges, the industry is embracing technological innovation and public engagement by investing in mechanical and chemical recycling methods while striving to reduce its carbon footprint. Regulatory frameworks such as extended producer responsibility laws in California and Oregon, alongside recycled content mandates in New Jersey, are driving demand for sustainable packaging solutions. Amid this backdrop, food-contact polypropylene (PP), one of the most widely used yet least recycled plastics, holds immense potential to meet regulatory standards and corporate sustainability goals.

Historically, recycling efforts have centered on bottles, including glass beer bottles and PET/HDPE containers, whose recycling processes are now well-established worldwide. However, other forms of plastic packaging, such as pots, tubs, and trays, were traditionally considered non-recyclable waste. This misconception persists in the United States, where municipalities often overlook PP pots, tubs, and trays (PTTs) due to historical precedents and a lack of awareness about their recyclability. Waste management companies, supported by organizations like Closed Loop Partners and The Recycling Partnership’s Polypropylene Recycling Coalition, are working to develop infrastructure for collecting PP products. Yet, many materials recovery facilities (MRFs) lack the necessary sorting stations for PP, which accounts for approximately 15% of total plastics volume.

Examining the United Kingdom's success in extracting value from food-contact PTTs offers insights into potential U.S. outcomes. According to RECOUP’s 2024 survey, U.K. collection rates for PTTs have risen from 20% in 2013 to a current rate of 40%, with 89% of local authorities providing curbside collection schemes that include PTTs. This shift has reduced general waste collection and increased plastic and paper recovery. Failing to create a circular economy for food-grade PP risks being overtaken by alternatives like paper and aluminum, which ironically possess higher carbon footprints. Despite representing two-thirds of consumer packaging by weight in the U.K., PP remains underutilized in recycling streams.

Creating a robust market for recycled PP involves moving beyond traditional commodity applications like shipping pallets and crates to closed-loop systems that incentivize recyclers. Achieving food-grade compliance standards for post-consumer PP requires substantial investment and innovative approaches. Proven, science-based processes exist to recycle post-consumer food-contact packaging into safe R-PP resins suitable for new packaging applications. Aligning design-for-recycling guidelines with circular economy requirements is essential. Minimizing pigment use and ensuring stability after multiple recycling cycles are critical factors. Additionally, developing technologies to remove labels, adhesives, inks, and contaminants enhances recyclability.

As the industry progresses, virgin resin producers can benefit by integrating recycled materials into their supply chains. Edward Kosior, a veteran in the plastics recycling sector, emphasizes the importance of addressing complex recycling issues through continuous reassessment and adaptation to emerging technologies. By closing the loop on post-consumer polypropylene, the industry can achieve meaningful progress toward sustainability and environmental stewardship.