PureCycle and Toppan integrate recyclate in films and thermoformed packs

PureCycle Technologies and Toppan have jointly developed flexible films and thermoformed packaging using high-quality recycled content to address global regulatory requirements.

The packaging companies have produced a snack bar wrapper containing more than 30% recyclate. The wrapper is said to offer the same performance capabilities as PureCycle’s PureFive resin for flexible packaging applications, while offering printability and functionality.

“The path forward for flexible packaging sustainability is one where food safety, regulatory compliance, performance, and environmental responsibility advance together, not in competition with one another,” says Astrid Torres, senior sustainability manager at Toppan Packaging, Americas.

“The snack bar wrapper we’ve developed showcases the printability and performance that leading brands demand, while incorporating meaningful recycled content. This is exactly the kind of packaging innovation needed to build a truly circular economy.”

Building on the wrapper with recycled content, the companies are targeting further thermoforming applications where brands seek recycled content solutions to comply with regulations.

Recyclate for thermoforming

PureCycle’s PureFive resin portfolio includes multiple grades designed for thermoformed applications such as snack cups, microwaveable containers, and other food-contact packaging formats.

PureCycle’s dissolution recycling process transforms post-consumer PP packaging into virgin-like PureFive resin, removing colors, odors, additives, and contaminants that can limit recycled material. The resulting resin meets US Food and Drug Administration standards for food-contact packaging and performs similarly to virgin resin, facilitating integration in manufacturing.

Glenn Jordan, director of R&D for thermoforming at Toppan Packaging, Americas, says: “At Toppan, we are committed to supporting brand owners meeting their recycled content goals without compromising on safety or performance. Our collaboration with PureCycle demonstrates how innovative partnerships can deliver commercially viable packaging that addresses regulatory requirements and brand expectations.”

Pete Dias, senior director of Market, Application & Product Development at PureCycle Technologies, adds: “Our partnership with Toppan exemplifies the power of collaboration in solving the packaging industry's most pressing sustainability challenges.”

“Toppan’s expertise in flexible and thermoformed packaging, combined with our high-quality recycled resin, enables brand owners to meet their sustainability commitments without compromising on quality, safety, or performance. Together, we’re proving that premium packaging performance can be achieved using recycled content.”