Ethan Clarke
Plastic yogurt containers are typically made from polystyrene (PS) or polypropylene (PP), chosen for their durability, flexibility, and ability to preserve freshness. The manufacturing process involves creating plastic pellets, which are then melted and molded into the desired shape through injection molding or thermoforming. Despite recycling initiatives, the real recycling rate for polypropylene is low due to contamination, toxic additives, and the difficulty of processing mixed plastics. Some companies, such as Stonyfield Farms, are transitioning to bio-plastic containers, while others like St. Benoit offer yogurt in returnable glass or ceramic containers.
| Characteristics | Values |
|---|---|
| Plastic type | Polypropylene or #5 plastics |
| Plastic manufacturer | Fujian Henglong Plastic Industrial Co., Ltd. (Honokage) |
| Other manufacturers | Airlite Plastics, Stonyfield Farms, Danone |
| Plastic properties | Durability, flexibility, ability to preserve freshness |
| Plastic production process | Injection molding, thermoforming |
| Plastic recycling | Difficult to recycle due to low value and contamination issues |
| Recycling rate | 2.7% of polypropylene containers recycled in 2018 according to EPA data |
| Alternative materials | PLA (bio-plastic), glass, ceramic |
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What You'll Learn
Yogurt containers are made from polystyrene or polypropylene
Plastic yogurt containers are typically made from polystyrene (PS) or polypropylene (PP). These materials are chosen for their durability, flexibility, and ability to preserve the freshness of the product. The manufacturing process for these containers begins with the creation of plastic pellets, which are then melted and molded into the desired shape through injection molding or thermoforming. Injection molding involves injecting molten plastic into a mold under high pressure to create a highly detailed and precise container. Thermoforming, on the other hand, involves heating a plastic sheet until it becomes pliable and then stretching it over a mold, which is then cooled to form the container shape.
Polystyrene is a popular material for yogurt containers in Europe, as it is effective in limiting aroma compound losses and avoiding the development of odor defects. It is often used for stirred yogurt, also known as European-style yogurt, which is creamy and smooth and typically includes added fruits and flavors. To enhance the appearance of polystyrene packaging and provide a barrier to light, titanium dioxide (TiO2) is often added.
Polypropylene, on the other hand, accounts for about 14% of US plastic production and is considered widely recyclable. It is used in various products, including yogurt containers, tubs, bottles, and jars. However, despite the claims of organizations like How2Recycle, the actual recycling rate of polypropylene is much lower. According to EPA data, only 2.7% of polypropylene containers and packaging were recycled in 2018, and this number decreases to just 0.6% when considering all forms of polypropylene.
The low recycling rate of polypropylene can be attributed to several factors. Firstly, it is not as clean or pure as other plastics and often contains toxic additives that make it challenging to turn them into usable items. Secondly, polypropylene is usually collected in bales of mixed plastic with various resins, making it difficult to recycle. Additionally, many curbside recycling programs no longer accept polypropylene due to its low recyclable value and China's ban on imported trash.
To properly recycle polypropylene yogurt containers, consumers can use resources like Recycle More Plastic's map to find nearby collection programs specifically for this type of plastic. Some stores, such as Whole Foods, also offer collection bins for polypropylene containers through programs like Preserve's Gimme 5.
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Polypropylene is difficult to recycle
Polypropylene (PP) is a thermoplastic polymer widely used in various applications, including the automotive, medical, and retail industries. It is also commonly used for food packaging, such as yogurt containers, due to its durability, flexibility, and ability to preserve freshness. Despite its versatility and demand, PP's recycling rate is incredibly low, estimated at only 2.7% to 3% for containers and packaging.
One significant challenge in recycling PP is its poor performance in mechanical recycling. PP is sensitive to high heat, often losing its chemical integrity, strength, and flexibility during the extrusion process. Recycled PP also tends to have inferior melt-flow rate (MFR), molecular weight, and thermal stability compared to virgin PP due to contamination or degradation during recycling. The high regulatory standards for food-safe plastic further limit the suitability of recycled PP for most market applications, as it often does not meet the required specifications within 2-3 recycling cycles.
The economics of PP recycling also present obstacles. The price of recycled PP is significantly higher than virgin PP, primarily due to the extensive testing, additives, and specialized sorting processes required for food-grade certification. Without dedicated large-scale recycling facilities, PP recycling faces challenges in achieving economies of scale.
Sorting and identifying PP for recycling can be complex due to its various forms and combinations with other materials. PP bags, for instance, must be collected, sorted, shredded, separated by color, and then compounded before effective processing. Most residential recycling receptacles and local recycling centers are not equipped to handle PP recycling, requiring consumers or companies to seek out specialized recyclers.
While some innovative companies, such as Purecycle in the US, are exploring solvent dissolution technology to improve PP recycling, the overall recycling rate for PP remains low. The accessibility of recycling programs and the real recycling rate are crucial metrics to consider when assessing the recyclability of PP. Despite efforts to improve recycling technologies, the challenges of sorting, contamination, and the economics of PP recycling persist.
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Yogurt containers often have foil lids, which are hard to recycle
Plastic yogurt containers are typically made from polystyrene (PS) or polypropylene (PP), with the latter accounting for about 14% of US plastic production. PP is chosen for its durability, flexibility, and ability to preserve freshness. However, despite being labelled as such, polypropylene is far more difficult to recycle into new products than is often implied. This is partly due to the fact that it is not as clean or pure as other plastics, often containing toxic additives that make it hard to reuse.
Yogurt containers often have foil lids, which are tricky to recycle because both the lid and the container come into contact with food, presenting a problem for recycling facilities that don't accept contaminated items. This means that even if a curbside program accepts polypropylene plastic, the foil lids may still need to be disposed of separately.
The recyclability of yogurt containers is further complicated by the fact that different brands use different types of plastic. For example, Chobani, Fage, and Yoplait containers are typically made from #5 plastic, while Chobani "Flip" yogurts use #6 plastic. Most curbside recycling programs do not accept #6 plastic, and many no longer accept #5 plastic either due to its low recyclable value and China's ban on imported trash.
As a result, consumers need to put in extra effort to recycle their yogurt containers properly. This may involve checking the number on the bottom of the container to identify the type of plastic, consulting the rules of their local curbside recycling program, and potentially dropping off the containers at a specialized collection program or participating store. Despite these challenges, proper recycling of yogurt containers is important to reduce waste and protect the environment.
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Stonyfield Farms uses PLA containers, but these are not widely recyclable
Stonyfield Farms, the world's largest organic yoghurt producer, has switched from polystyrene to PLA (polylactic acid) containers for its multipack form/fill/seal containers. This is believed to be the first use of PLA for f/f/s dairy containers. PLA is made from plants, mainly corn.
While Stonyfield Farms' previous multipack cups were made from polystyrene, which is not recyclable and potentially toxic, their new PLA containers are not widely recyclable either. The company is looking at feedstock recovery, recycling the containers back into PLA pellets that can be reused to make new containers. However, there are currently only two facilities that recycle PLA, one in Belgium and one in Nebraska, and Stonyfield cannot recycle its containers there due to the metalized PET (#1 plastic) lid. The company is working on developing a new lid and a take-back program for the containers.
The switch to PLA is part of Stonyfield Farms' efforts to reduce its environmental impact. The new PLA cups result in 48% less greenhouse gas emissions compared to their previous packaging. The company has a history of trendsetting when it comes to environmentally friendly packaging, being the first to lightweight its yoghurt cups in the 1990s and the first to eliminate the plastic lid in favour of flexible foil lidding in 2002.
While some applaud Stonyfield Farms' attempts to find a healthier and more environmentally friendly alternative to single-serving packaging, others criticise the move, arguing that the PLA cups will ruin the recycling stream as customers will try to recycle them, mixing them with real plastic and making all of it useless. They suggest that the company should instead focus on using recycled plastic that can be recycled again.
The issue of recycling yoghurt containers is not unique to Stonyfield Farms. Many curbside recycling programs no longer accept polypropylene plastic, which is commonly used for yoghurt containers, due to its low recyclable value and China's ban on imported trash. This has led to confusion among consumers about how to properly recycle their yoghurt containers. While some programs and drop-off locations do accept polypropylene plastic, the real recycling rate for this material is low, with only 2.7% of polypropylene containers and packaging recycled in 2018 according to EPA data.
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Airlite offers recyclable polypropylene yogurt containers
Plastic yogurt containers are typically made from polystyrene (PS) or polypropylene (PP), with the latter being more common. Polypropylene is favoured for its durability, flexibility, and ability to preserve the product's freshness. However, polypropylene is difficult to recycle into new products. This is due to the plastic often containing toxic additives, and the difficulty in separating it from other plastics during the recycling process.
Airlite Plastics offers recyclable polypropylene yogurt containers. Their yogurt cup portfolio includes traditional round cups, as well as cups with rounded tops and "sqround" bottoms for a unique look. Airlite's IML cups with in-mold labelling are their most striking decoration option, but all cups can be decorated with either traditional dry offset printing, flexographic printing, or in-mold labelling. Their cups are made from mono-material PP, meaning the label and cup can be recycled together without needing to be separated. Airlite's commitment to sustainability is further demonstrated by their achievement of ISCC PLUS certification and their pledge to join the U.S. Plastics Pact.
Airlite's yogurt cups come in a variety of sizes, ranging from 80mm to 95mm in diameter and 4oz to 32oz in volume. Their injection-molded containers are ideal for single-serve and multi-serve yogurt cups. Injection molding involves injecting molten plastic into a mold under high pressure, resulting in a highly detailed and precise container.
While Airlite's recyclable yogurt containers are a step towards sustainability, it is important to note that the accessibility of recycling programs and the real recycling rate are separate issues. Consumers should be aware of the recycling options available in their area and the percentage of collected polypropylene that is actually recycled.
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Frequently asked questions
Some companies that make plastic for yogurt containers include Airlite Plastics, Fujian Henglong Plastic Industrial Co., Ltd. (Honokage), and Stonyfield Farms.
Plastic yogurt containers are typically made from polystyrene (PS) or polypropylene (PP), which is a durable and flexible material that can preserve the product's freshness.
Yogurt containers are technically recyclable, but in practice, they often are not recycled due to the difficulty of processing polypropylene. Only 2.7% of polypropylene containers and packaging were recycled in 2018, according to EPA data.
