Berry Global expands North American polypropylene capacity as foodservice demand soars

15 Sep 2021 --- Berry Global has announced plans to expand its foodservice packaging manufacturing operations in North America as part of its long-term strategic growth commitments. 

This more than US$110 million investment will expand its proprietary and industry-leading polypropylene (PP) thermoforming capabilities for manufacturing clear drink cups and lids for quick-service restaurants, coffee shops, convenience stores, and other foodservice markets.

The North American expansion is expected to be operational in 2022 and add 200 new jobs at Berry facilities. 

Customizable clear cups
The clear cup design fills an increasing demand for a cup that showcases a premium brand image and beverage appeal and improves restaurant operation efficiencies while offering a more environmentally sustainable packaging option.

Berry says foodservice brand owners are steadily increasing their forecasted production volumes for access to the company’s 30-plus active patents across clear cups and lids.

Additionally, customized plastic cup and lid brand owner solutions are a rapidly increasing market trend, pulling volume from alternative substrates since 2017.

Consequently, Berry says it has demonstrated its market leadership, outpacing market trends and growing its sales by a forecasted 60% against a 2017 baseline.

Polypropylene eco-credentials
PP is widely regarded as one of the most environmentally responsible transparent substrates available on the market today. The material offers lower greenhouse gas emissions and reduced energy and water usage in comparison to PET.

Berry’s increased capacity will produce clear cups and clear lids made of PP, which can be recycled into new packaging or one of the material’s many other end markets.

According to the 2019 US Post-Consumer Plastic Recycling Data Dashboard, PP cups and containers are the third most curbside-recycled plastic by consumers.

Support for post-consumer resin
Berry’s expanded capacity will also support future production of clear cups and lids that incorporate post-consumer resin and recyclable materials, in which Berry continues to invest.

“Foodservice brands are moving to meet their own sustainability goals, and PP provides one of the lowest impact substrate options to help them get there,” notes Bill Norman, president of Berry Global Consumer Packaging North America.

“With Berry’s long record of innovation in foodservice packaging and this expanded capacity, we will deliver on the need to bring greater circularity to the disposable beverage cup market.”

This initiative is in line with Berry’s efforts to improve PP’s curbside recycling. The company recently announced it had joined The Recycling Partnership’s Polypropylene Recycling to help increase recycling access to PP.

The coalition awarded US$4.2 million in grants to 13 recycling facilities to positively impact nearly 15 million Americans, almost 6% of the US population.

Edited by Joshua Poole

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