INNOVATION | PACKAGING


sion of recycled plastics is to increase the material flow in the loop while maintaining high quality. When input materials vary, robust systems are essential, and filtration, degassing and a thorough understanding of the process define the process stability and the product quality. Ultimately, the circular economy is achieved when the material’s design, collection, sorting, washing and extrusion are compatible and the recyclate is subsequently used in new products of equal quality. The integra- tion of the chain has proved to be of advantage for several technology suppliers. To increase the role of recycling in meeting the rising demand for plastic in future, a set of reliable rules is required that makes investment possible. Regulations such as those for packaging (PPWR) are important milestones. “We need a standardised system to make recyclates more attractive. Only then will recycling be able to establish itself as part of a long-term raw materials strategy”, said Hackl.


Circular PP Last September, for the first time recycled polypro- pylene was approved for food contact under the European Standard (EU 2022/1616). Prevented Ocean Plastic sourced PP cups collected in East Borneo. This new initiative brings together global partners and in its first year it is expected to prevent 500m PP cups from entering the ocean. Prevented Ocean Plastic has established a


franchise model for collection, supported by Danone Aqua in Indonesia. The for-profit model, launched at the beginning of the decade, has since been financially supported by five separate institu- tions, establishing the unique capability to sort and customise input feedstock for high-quality recycling.


Right: PP cups collected by Prevented Ocean Plastic in East Borneo. In its first year it is expected to divert 500m PP cups to recycling


Once collected, sorted and washed, the material


is then processed by Petman using technology from Starlinger Viscotec, turning it into high-quality, food- safe recycled polypropylene (rPP) and then supplied by Bantam Materials UK (owner of the Prevented Ocean Plastic programme) to offtakers. Early adopters include Spectra Packaging, to produce blow moulded and injection moulded packaging. Interzero is opening a new site in Dessau,


Germany, targeting the production of food-grade PP regranulate. The company has developed a process to recover food-grade and near-food grade material obtained from Germany’s light- weight packaging collection system (dual system Gelber Sack, or Yellow Bag) through mechanical processing. According to a 2024 study carried out by Pforzheim University, around 11% of plastic packaging in the Gelber Sack is made out of PP. The company has worked to develop sorting


and recycling processes to produce mrPP (me- chanically recycled PP). Though the company does not provide detailed information about its technol- ogy, it confirms that it is building a pilot plant to produce 5,000 tonnes of mrPP granulate per year, and that all tests relating to sorting and recycling, as well as initial tests for the use of the material in food packaging, have been completed success- fully. The EFSA approval for the use of the regranu- lates in food-grade, near-food-grade and cosmetic applications is being initiated. “The PPWR is increasing the pressure to adapt


regulations. A strong European circular economy now needs room to manoeuvre. In the end, what matters is how safe and functional the product is – regardless of the feedstock,” said Interzero CEO Jan Kroker. “Achieving the goals of the PPWR will require strong technologies working together. For PP recycling, this means using mechanical and chemical recycling in a complementary way, in order to keep as many recyclable materials in the loop as possible. The task now is to create the right framework conditions so that this technological know-how can be used.” Several suppliers are delivering either resins or semi-finished products which already have the required amount of recycled content to comply with regulations. The Swedish company Scanfill offers a plastic foil consisting of 30% post-consumer recycled PP, developed to meet the PPWR requirements. The material is obtained from collected plastics cups from coastal areas. A partner uses an “advanced recycling process”, states Scanfill without specifying any further detail, and both the partner and Scanfill ensure quality and traceability. The foil is approved for food contact, is available in various levels of


14 PLASTICS RECYCLING WORLD | September 2026 www.plasticsrecyclingworld.com


IMAGE: PREVENTED OCEAN PLASTIC


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