International Production & Processing Expo: Tekni-Plex unveils foam PP trays and PCR egg carton

27 Jan 2022 --- Tekni-Plex Consumer Products is launching foam polypropylene processor trays for fresh food products such as meat, poultry, pork, fruits and vegetables. The US-headquartered company is also introducing a new version of its Dolco ProPlus egg carton, containing 25% post-consumer recycled (PCR) foam polystyrene. 

The products are on display at the ongoing International Production & Processing Expo in Atlanta, US (January 25-27).

“Expectations for the packaging industry are changing, so we’re working with new substrates to create material alternatives that meet the needs of our customers and their consumers,” says Chuck Gallagher, vice president of business development at Dolco Packaging, part of the Tekni-Plex Consumer Products Division.

Foam polypropylene is durable, lightweight, heat-resistant and FDA-approved for direct food contact. The material is also a drop-in replacement for common foam polystyrene trays, meaning businesses do not need to retool their packing equipment at added costs.

A lighter tray solution
Like foam polystyrene, foam polypropylene requires less material to create high-quality products, using minimal resources. When compared to solid PET trays, for example, foam polypropylene weighs half as much, says Dolco Packaging.

“Due to the material’s efficiency, we believe foam polypropylene will be a valuable competitive solution when compared to other tray alternatives, allowing brands and retailers to meet their business goals,” continues Gallagher.

A major wholesale company will debut products in the new foam polypropylene meat trays. As it looks similar to foam polystyrene, foam polypropylene will have a familiar appearance to consumers, allowing brands and retailers to maintain a recognizable fresh, packed-in-store product appearance.

“Investing in new technologies and new materials allows us the capability and the flexibility to find solutions to the major packaging issues our customers are facing today,” says Gallagher. “As we diversify our material offerings, our goal is to continue to innovate with value-added solutions that meet the needs of our customers, their consumers, and future generations.”Dolco Packaging’s egg carton containing 25% PCR foam polystyrene.

Egging on the circular economy
Tekni-Plex Consumer Products has also introduced a new version of its Dolco ProPlus egg carton containing 25% PCR foam polystyrene.

“We have a responsibility to lead the way by innovating products that help maintain the integrity of the food supply chain while also minimizing environmental impact,” comments Jay Arnold, vice president and general manager at Dolco Packaging. “This exciting new venture into polystyrene PCR is another alternative we can now offer customers.”

The new resin contains recycled post-consumer waste, which Dolco Packaging uses to manufacture egg cartons with the same performance and characteristics as cartons using conventional resin. Packers, retailers, and consumers can expect the same superior quality and protection while reducing their carbon footprint.

“These cartons can be recycled multiple times through advanced recycling without compromising quality or performance, while also supporting the packaging industry’s goal of moving toward a true circular economy,” adds Arnold.

A major egg packer will be the first customer to utilize the new cartons as part of its commitment to delivering products in efficient protection solutions, minimizing food waste and reducing the use of virgin materials.

PET egg cartons
Dolco Packaging also currently offers 100% PCR PET egg cartons and will continue to promote the use of PCR in its products.

“If all plastics were properly collected and recycled, the packaging industry could use more PCR resin, saving resources while still providing economic, high-performance packages to the market,” notes Arnold.

All Dolco Packaging facilities are collection points for foam polystyrene with both mail-in and drop-off options.

Edited by Joshua Poole