Cheese packaging circularity gains traction as plastics recyclability legislation looms

01 Oct 2020 --- Packaged cheese is as popular as ever. The USDA Economic Research Service (ERS) highlights that US dairy consumption has hit a “rate never seen before,” driven by strong domestic demand for cheese. However, flexible plastic cheese packaging typically goes unrecycled.

Some suppliers are exploring options to keep cheese packaging off the single-use waste mountain through recyclable-by-design packaging innovation, material reduction and closed-loop recycling programs.

Impending legislation is accelerating the recyclability transition. The European Council has approved the implementation of a plastic tax starting January 1, 2021, that foresees a €0.80/kg levy on non-recycled plastic.

Likewise, the UK government has proposed a £200 (US$263) per ton tax for plastic packaging with less than 30 percent recycled content that will take effect from April 2022.

Mondi’s recycle-ready trays
Targeting recyclability in cheese packaging, Mondi launched an 80 percent paper-based packaging solution for cold meats and cheese in September.

Mondi says the PerFORMing removable range is Europe’s first paper-based food tray that allows the paper and plastic film components to be easily separated for recycling.Mondi says PerFORMing is Europe’s first paper-based food tray to enable easy separation of paper and plastic film components for recycling.

“The removable plastic film is a co-extruded high barrier material that extends product shelf life,” Falk Paulsen, sales and business development director, Mondi Extrusion Solutions, tells PackagingInsights.

“When the product is fully consumed, the film can be separated from the formable paper shell and placed in the yellow bin, while the paper tray is recycled in the paper bin.”

The tray reduces Austrian dairy producer SalzburgMilch’s plastic by approximately 40 tons per year, and carbon footprint by two-thirds, compared to its previously used rigid plastic trays.

Pilgrims Choice’s plastic-reducing Megablock
Aiming at material reduction, Ornua Foods UK launched the Megablock, a new packaging that delivers a 40 percent plastic reduction on Pilgrims Choice cheddar, and a projected 83-ton plastic saving annually.

“Purchasing habits are heavily influenced by sustainability, with 89 percent of UK consumers expecting brands to invest in this area,” Mike Harper, Ornua Foods UK’s marketing director, shares with PackagingInsights.

“‘Waste and pollution’ and ‘sustainability of the planet’ are the two top areas of concern for consumers.”Pilgrims Choice’s Megablock delivers a 40 percent plastic reduction.

The greater depth of the new block results in a chunkier block shape, making it easier for consumers to handle the cheese when cutting, grating or slicing.

“We surveyed consumer groups, and the Megablock was well received with regards to the plastic saving and the new block shape’s usage benefits,” Harper notes.

Wipak’s thinnest reclosable film
With material savings in mind, European flexible packaging provider Wipak unveiled its thinnest reclosable lidding film for sliced cheese and meat.

The Repak Top 65 XX PET is 20 percent thinner than comparable products and produces around 15 percent less carbon footprint.

The bottom film can be replaced with a recyclable material film, resulting in a 60 percent lower carbon footprint than more conventional solutions.The Repak Top 65 XX PET uses Wipak’s thinnest reclosable lidding film for sliced cheese.

TerraCycle recycling partnerships
Ornua Foods UK announced a long-term partnership with waste management leader TerraCycle to support the recycling of plastic film used in cheese packaging.

“TerraCycle is committed to ‘Eliminating the Idea of Waste’ by recycling the ‘non-recyclable’ to divert millions of pounds of waste from landfills and incinerators each month,” Harper continues. 

“With the support of Ornua, TerraCycle allows UK consumers to recycle flexible plastic cheese packaging, including Pilgrims Choice and other branded and own-label cheeses.”

UK’s first flexible cheese pack recycling program
Similarly, UK cheese manufacturer Cathedral City partnered with Terracycle to deliver on calls for improved recycling efficiencies.

The collaboration supports the UK’s first flexible film cheese packaging recycling program for the entire cheese category – no matter the brand.

The program’s objective is to encourage consumers to collect their Cathedral City cheese packaging and responsibly dispose of it at one of the scheme’s UK public access drop off points.

“We set these programs up to reach as many people as possible in the UK. If a collector does not have a drop-off location nearby, they are welcome to set one up themselves,” Julien Tremblin, Terracycle’s head of brand partnerships, tells PackagingInsights.

“If this is not an option, it is worth noting that the emissions that result from processing this waste – including transportation – are still lower than sending it to landfill and producing more virgin plastics as a result.”Cathedral City’s partnership with Terracycle supports the UK’s first flexible film cheese packaging recycling program.

Tesco’s circular cheese packaging
A Tesco’s trial is demonstrating that soft plastic can be continuously recycled into food-grade cheese packaging. The cheese packaging is on sale in Tesco’s stores.

The supermarket giant is partnering with Plastic Energy, Sabic, Sealed Air and Bradburys Cheese to prove soft plastic can be recycled as part of a closed-loop recycling system.

Soft plastic material collected from Tesco customers is sent to Plastic Energy for conversion into oil through an advanced pyrolysis recycling process.

The recycled oil is used by Sabic in its production process as an alternative to traditional fossil materials to make new plastic pellets that are as safe and effective as virgin plastic. 

The pellets are used by Sealed Air to create 30 percent recycled soft packaging for Tesco’s cheese supplier, Bradburys.Tesco partnered with Plastic Energy, SABIC, Sealed Air and Bradburys Cheese to prove soft plastic can be recycled as part of a closed-loop recycling system.

According to the 2019 UK Household Plastic Collection Survey, the UK uses almost 400,000 tons of soft plastics every year, but under 21,000 tons are collected, and typically recycled into non-food grade material.

Philadelphia pivots to recycled plastic
Mondelēz International revealed that its European-sold Philadelphia cream cheese packaging will be produced using 5 percent recycled plastic as of 2022.

According to the snacking giant, the move makes Philadelphia the first cream cheese brand to use recycled plastic in its packaging.

“By recovering and diverting waste that would have otherwise been sent to landfill or incineration, we are working towards our common goal of promoting a circular economy,” says Jean-Marc Galvez, Berry Global’s president consumer packaging international.

Berry Global is collaborating with Mondelēz to supply the recycled plastic for Philadelphia cream cheese. The package contains plastic material recovered using advanced recycling technology from Berry’s partnership with Sabic.

By Joshua Poole