Grounded Packaging launches PE pouch with “world’s highest” post-consumer recyclate percentage

29 Jun 2022 --- Grounded Packaging is launching RE: Mono, a recyclable, flexible packaging solution made of 83% recycled materials that boasts a 57% reduced environmental footprint compared to virgin plastic packaging. The new product reportedly contains the highest volume of post-consumer recycled (PCR) content currently available worldwide for food contact pouches and other flexible packaging formats.

“The most exciting thing about RE: Mono is that this material has the potential to replace a significant portion of single-use virgin plastic packaging that goes into supermarkets,” Ben Grant, co-founder at Grounded, tells PackagingInsights. 

“What most people don’t understand is that there are currently very few solutions that have the potential to drive wholesale change to the flexible packaging space in the short term, and this is one.”

“The potential cumulative effect of moving almost 100% of the material to PCR content and having that be readily recyclable and cost comparable is exciting,” he adds. 

Milk bottles and plastic bags
Grounded’s new film laminate offers food manufacturers an environmentally sustainable alternative packaging solution to traditional products that are often non-recyclable and typically end up in landfills or the environment. 

RE: Mono is a monomaterial, recyclable, low-density PE soft and flexible material.The end-to-end packaging supplier says its new material originates from the idea to design an innovative packaging product that limits environmental impact while still prioritizing functionality, convenience and food safety. 

To achieve this, Grounded’s PCR film laminate is made from disposed of plastic from recycling streams, such as milk bottles and plastic bags.

Overcoming material challenges
Grant explains that there were several challenges to getting this type of material to work. “The first relates to obtaining a recycled material quality that allows it to meet food contact certification standards, which historically has been extremely challenging for PE,” he says.

“Over the last few years we have worked closely with our supply chain partners to source the best quality material and then to undergo the certification process.”

“On top of that there were also a number of challenges around achieving the necessary barrier rates and printability performance, and again, we went through an extensive testing process to ensure we could deliver something that works both at scale and across a wide range of potential foodstuffs,” asserts Grant. 

Achieving the unachievable
Achieving the properties of RE: Mono is a groundbreaking R&D achievement, says the company. For years, converting a high percentage of PCR content into film and having it meet food contact certification standards has been thought to be unachievable – particularly so while maintaining quality and cost. Grounded’s RE: Mono reduces environmental footprint by 57% compared to virgin plastic packaging.

Grounded has been working with partners to control sourcing, material sortation, and blending within their PCR material to achieve a higher quality product fit for food contact within all their products.

“The packaging we’re launching today has been deemed unattainable by other flexible packaging manufacturers. We look forward to bringing to market more [environmentally] sustainable products like RE: Mono to help consumers and brands join the fight against the climate crisis,” adds Grant. 

Reducing carbon 
Global plastic production was estimated to reach 367 million metric tons in 2020. Moreover, nearly 40% of the plastic produced is used for F&B packaging and is often single-use. 

As an increasing number of food manufacturers prioritize environmental sustainability goals, Grounded’s RE: Mono solutions offer an alternative that reduces environmental footprint by 57% compared to virgin plastic packaging. 

Furthermore, Grounded says it is on a mission to remove 4 million kg of ocean-bound plastic by the end of 2022. 

“There is no silver bullet for what is the ‘right’ sustainability solution in this space. But what this solution represents is an opportunity to have an enormous positive impact in terms of reducing carbon and moving toward a functioning circular economy. And up until now, most of the big players have thought a solution like this was impossible to achieve,” concludes Grant.

By Natalie Schwertheim