Ethan Clarke
Thermoformed plastic is used in a variety of packaging, including cups, lids, clamshells, bowls, and containers for produce, deli, bakery, and takeout. While not all thermoforms are PET, most are, and PET thermoform packaging is technically recyclable with PET bottles. However, the recyclability of thermoformed plastic depends on various factors, and there are challenges associated with its recycling.
| Characteristics | Values |
|---|---|
| Recyclability | Technically recyclable with PET bottles, but not all thermoforms are PET |
| Recycling challenges | Lack of knowledge about what is and isn't recyclable, brand commitments to sustainability, technical, logistical and market obstacles |
| Recycling rates | Between 2011 and 2023, domestic reclamation of PET thermoforms more than quadrupled in the US and Canada |
| Recycling guidelines | APR Design Guide, APR Global Design Catalog, NAPCOR best practices document |
| Recycling partners | Foodservice Packaging Institute (FPI), Association of Plastic Recyclers (APR), National Association for PET Container Resources (NAPCOR), Northeast Recycling Council (NERC), The Recycling Partnership, Sustainable Packaging Coalition (SPC), Petcore Europe |
| Recycling technology | Reprocessing advancements to address intrinsic viscosity (IV) issues, poly-condensation step to repair mechanical properties and remove volatile contaminants |
| Recycling design | Removing aggressive adhesives, using approved labels, new combinations of glue/labels, redesigned soaker pads |
| Recycling goals | Unilever aims to make plastic packaging 100% recyclable, reusable or compostable by 2025 |
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What You'll Learn
- Polyethylene terephthalate (PET) thermoform packaging is recyclable
- Thermoform packaging is used in cups, lids, clamshells, bowls, etc
- The global thermoform packaging market was estimated at $39.86 billion in 2018
- The Foodservice Packaging Institute (FPI) is examining PET thermoform packaging recycling
- The Association of Plastic Recyclers (APR) has developed design-for-recyclability guidelines for PET thermoforms
Polyethylene terephthalate (PET) thermoform packaging is recyclable
PET thermoform packaging can be recycled with PET bottles, and many PET reclaimers accept thermoforms in bottle bales. However, there are challenges to recycling PET thermoforms. For instance, only a small percentage of PET thermoforms make it to recycling bins, and there are technical challenges in mixing PET thermoforms with bales of more valuable PET bottles. Additionally, the low prices of virgin resin create a competitive challenge.
Despite these challenges, efforts are being made to increase the recycling of PET thermoforms. Organizations such as the Foodservice Packaging Institute (FPI), the Association of Plastic Recyclers (APR), the National Association for PET Container Resources (NAPCOR), and others are working together to pool data and resources to improve the recyclability of PET thermoforms. They are exploring technical, logistical, and market obstacles and seeking solutions through collaboration with industry peers.
The recyclability of PET thermoforms supports environmental sustainability, and they are preferred by companies seeking circular packaging solutions. PET thermoforms can achieve high levels of recycled content while maintaining safety and performance standards in food-grade applications. The ability to recycle PET thermoforms repeatedly without significant degradation in quality further enhances their sustainability credentials.
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Thermoform packaging is used in cups, lids, clamshells, bowls, etc
Thermoforming is a process that enables the creation of packaging for a diverse range of rigid food packaging applications. It is particularly useful for disposable food containers, trays, clamshells, and platters, which can be sealed with a film or fitted with a lid. Thermoform packaging is used in cups, lids, clamshells, bowls, and other types of consumer packaging.
Thermoformed cups have become an integral part of the beverage industry, offering convenience and practicality. They are versatile, durable, leakproof, and stackable, making them a popular choice for businesses and consumers alike. The cups can be customized with logos and promotional messages, enhancing their visual appeal and serving as a marketing tool.
Thermoformed clamshells are another popular packaging solution. They are hinged containers with two halves that fold together to secure and protect food items. Clamshells are widely used for packaging ready-to-eat meals, fruits, vegetables, sandwiches, and other grab-and-go items. They provide a tamper-evident and contamination-free packaging solution, ensuring the integrity and freshness of the packaged food.
Thermoform packaging made of PET plastic resin is technically recyclable with PET bottles. However, not all thermoforms are PET, and there are challenges associated with PET thermoform recycling. Organizations like the Foodservice Packaging Institute (FPI), the Association of Plastic Recyclers (APR), and the National Association for PET Container Resources (NAPCOR) are working to increase the recyclability of PET thermoforms and address technical, logistical, and market obstacles.
The APR Design® Guide is a valuable resource for packaging designers, providing comprehensive guidelines to ensure packaging is designed for recyclability. It offers classifications for package design features according to four recyclability categories. By following these guidelines, brands and packaging companies can improve the sustainability of their products.
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The global thermoform packaging market was estimated at $39.86 billion in 2018
Thermoform packaging is a valuable and sustainable material that is technically recyclable, although not all thermoforms are made of PET plastic resin, which is recyclable with PET bottles. The global thermoform packaging market was estimated at $39.86 billion in 2018 and has been growing steadily since. Between 2019 and 2025, the market is projected to grow at a compound annual rate of 4.7%, reaching \$51.96 billion by 2023 and \$88.50 billion by 2030, exhibiting a CAGR of 7.91% during the forecast period. This growth is driven by several factors, including the increasing demand for packaged food, the rise of e-food delivery platforms, the expansion of the pharmaceutical sector, and the growing demand for sustainable and cost-effective packaging solutions for electronics and electrical products.
The demand for packaged food, including prepared food, meat, seafood, and bakery products, has been a significant contributor to the growth of the thermoform packaging market. The convenience and accessibility offered by packaged food options have made them increasingly popular among consumers. Additionally, the rising popularity of Modified Atmosphere Packaging (MAP) for food products, which extends the shelf life of food by employing a controlled gaseous mixture within thermoform containers, is expected to further boost market growth.
The expansion of the foodservice industry, driven by the increasing popularity of e-food delivery platforms and changing lifestyles, has also contributed to the demand for thermoform packaging. Thermoformed products such as trays, containers, cups, and plates are widely utilized by the foodservice industry for table offerings and parcel packaging. The cost-effectiveness, lightweight nature, and aesthetic appeal of thermoform packaging make it a popular choice for packaged food manufacturers.
Another key factor driving the growth of the thermoform packaging market is the expansion of the pharmaceutical sector in various developing countries. The increasing demand for pharmaceutical drugs has encouraged the adoption of sustainable and cost-effective packaging solutions, such as thermoformed packaging products. Between 2014 and 2019, the pharmaceutical sectors in Brazil, China, and India experienced significant growth rates of 11.2%, 6.9%, and 11.1%, respectively. This substantial growth in the pharmaceutical industries globally is generating a significant demand for thermoform packaging, thereby driving market growth.
The electronics and electrical sector is also contributing to the growth of the thermoform packaging market. Manufacturers in this industry are increasingly turning to thermoform packaging products such as clamshells, trays, and blisters to meet the demand for sustainable and cost-effective packaging solutions for their products. The India Brand Equity Foundation reports that India's consumer electronics and home appliance sector generated USD 9.84 billion in revenue in 2021 and is projected to reach USD 21.18 billion by 2025. This growth in the electronics and electrical sector is expected to further boost the demand for thermoform packaging.
It is worth noting that while the thermoform packaging market is expanding, it also faces challenges. One significant challenge is the impact of crude oil price volatility on the cost of raw materials. The recent COVID-19 outbreak and the Russia-Ukraine War have caused fluctuations in crude oil prices, affecting the production costs of downstream products used in thermoformed packaging. Additionally, consumers are increasingly demanding customizable designs, longer shelf life, and superior contamination protection, which presents technical and design complexities for manufacturers.
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The Foodservice Packaging Institute (FPI) is examining PET thermoform packaging recycling
The Foodservice Packaging Institute (FPI) is working with several trade organizations and companies to examine the recycling of polyethylene terephthalate (PET) thermoform packaging. The project aims to establish a common understanding of the most significant opportunities to increase PET thermoform recycling and define the most cost-effective and practical pathways for recovery.
The study is being conducted by Resource Recycling Systems (RRS) in Ann Arbor, Michigan, and is expected to be completed in the fall. FPI has organized a group that includes the Association of Plastic Recyclers (APR), the National Association for PET Container Resources (NAPCOR), the Northeast Recycling Council (NERC), The Recycling Partnership, and the Sustainable Packaging Coalition (SPC).
The group will pool data and resources to gain a more thorough understanding of the complex issues surrounding PET thermoform recycling. Some of the challenges with thermoforms include problematic labels, non-PET look-alike packaging, and greater fines generation during the recycling process. In addition, thermoformed PET has a lower intrinsic viscosity than bottle-grade PET, which poses technical and logistical collection and sorting challenges.
Despite these challenges, some reprocessors are actively seeking out this material. For example, Vernon, California-based rPlanet Earth, a company that produces packaging from recycled PET, has partnered with Green Impact Plastics to purchase post-consumer thermoform bales from California and other southern states. This partnership addresses the shortfall of available post-consumer recycled PET to meet content goals.
The study will also explore the potential limitations, obstacles, viability, costs, and related metrics of PET thermoform curbside recycling and other potential recycling pathways. It is designed to help brands and packaging companies improve the sustainability of their packaging and increase recycling rates, providing a valuable recycled material to the industry.
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The Association of Plastic Recyclers (APR) has developed design-for-recyclability guidelines for PET thermoforms
The Association of Plastic Recyclers (APR) has developed a set of design-for-recyclability guidelines for PET thermoforms, aiming to enhance the recyclability of this material. PET, or polyethylene terephthalate, is a type of plastic resin commonly used in thermoform packaging. While PET thermoforms are technically recyclable, various challenges and issues remain.
The APR Design® Guide is a comprehensive set of guidelines that helps companies ensure their packaging designs are compatible with recycling processes. It provides detailed information on various aspects, including base resin, additives, colour, labels, caps/dispensers, and postconsumer content. The guide is recognised as the authority on designing plastic packaging for recyclability in North America and is frequently referenced by leading organisations worldwide.
One of the key benefits of the APR Design® Guide is its ability to help companies minimise contamination and improve productivity in the recycling process. By following the guide's recommendations, companies can reduce costs and improve the quality of post-consumer resin (PCR). Additionally, the guide offers laboratory test protocols that assess the impact of design features on the recyclability of plastic packaging.
The APR has also developed the APR Global Design Catalog, which provides access to current plastic packaging recyclability guidelines worldwide. This resource is particularly useful for companies seeking confirmation that their supplier's products are designed with recycling in mind. Furthermore, the APR offers PCR Certification to provide transparency and support a reliable PCR market.
The APR has recognised the recyclability of several packaging innovations, including HDPE tubes, PET aerosol containers, and PP thermoforms. These innovations have received recyclability recognition letters from the APR, indicating their compatibility with widely used plastics recycling processes. The APR also collaborates with various organisations, such as the Foodservice Packaging Institute (FPI) and the National Association for PET Container Resources (NAPCOR), to further enhance the recyclability of PET thermoforms.
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Frequently asked questions
PET stands for polyethylene terephthalate, a type of plastic resin used in thermoform packaging. PET thermoforms include items like clamshells, tubs, trays, egg cartons, and other rigid, non-bottle packaging.
Yes, technically, PET thermoform plastic is recyclable. However, not all thermoforms are made of PET, and there are challenges associated with recycling them. Some municipal recycling programs have stopped collecting thermoformed containers, and not all recycling plants accept them.
To recycle PET thermoform plastic, it is essential to check with your local recycling program or waste management service to see what specific guidelines and restrictions they have in place. Some plants may not accept thermoformed plastics, while others might have certain requirements for their collection and processing.
One significant challenge in recycling PET thermoform plastic is the intrinsic viscosity (IV) of the material, which tends to decrease with each recycling process, resulting in a more brittle and lower-quality material. Additionally, the glues used on labels and soaker pads in thermoform packaging can compromise the plastic flake cleaning process, making it difficult to recycle.
