PureCycle Technologies, Inc. (Nasdaq: PCT) has announced a significant advancement in sustainable packaging by successfully producing and trialing white, cavitated biaxially oriented polypropylene (BOPP) film in partnership with Innovia Films, a leader in material science and a prominent manufacturer of packaging, graphics, and label films. This innovative film is created using PureCycle’s PureFive Choice™ resin and incorporates over 40% post-consumer recycled (PCR) materials. It is targeted at brand owners looking to enhance their products with recycled components.
The white, cavitated BOPP film plays an essential role in various consumer packaging formats, known for its opacity, lightweight nature, and printability. It serves numerous food-contact applications such as wrappers for candies, ice cream novelties, and various snacks, as well as roll-fed labels. The film’s unique cavitated design provides a paper-like texture and an optimal surface for printing, all while ensuring the necessary mechanical strength and moisture resistance for food safety. The successful creation of this film type using PureFive® resin signifies a pivotal expansion of possibilities with post-consumer recycled polypropylene in sophisticated flexible packaging environments.
This achievement coincides with transformative changes in the global packaging sphere. Legislation on Extended Producer Responsibility (EPR) is influencing purchasing choices for flexible packaging manufacturers and brand owners. For instance, California’s SB 54 imposes reductions on virgin plastic, prompting modifications throughout the supply chain. Similarly, the Packaging and Packaging Waste Regulation (PPWR) in Europe requires increased targets for recycled content in plastic packaging beginning in 2030, especially for film and flexible formats that have historically struggled to secure adequate PCR supply. PureCycle’s PureFive® resin stands out as a commercially available option compliant with food-contact standards, equipping converters and brand owners to meet these regulations effectively, without compromising quality or processing efficiency.
“This film produced with PureFive® resin is a significant milestone in enhancing the sustainability of flexible packaging,” stated Chris Freshwater, Market Manager at Innovia Films. “Our R&D teams are continually striving to boost product sustainability. PureCycle’s revolutionary dissolution recycling technology is a true innovation. It allows us to integrate post-consumer recycled content while reducing energy usage during recycling.”
In addition to regulatory pressures, the push for PCR-content flexible packaging is being spurred by large consumer goods companies that have voluntarily committed to the Ellen MacArthur Foundation’s New Plastics Economy Global Commitment. Numerous brand owners aim to include recycled materials, eliminate unnecessary plastics, and promote circularity in their packaging. White, cavitated BOPP film, commonly used in snack and confectionery products by major global food brands, has posed challenges for integrating significant recycled content. This collaboration effectively fills that gap, offering brand owners a viable and scalable route to fulfill their commitments to the Ellen MacArthur Foundation.
“The successful production of white, cavitated BOPP film is a groundbreaking development for PureCycle and the flexible packaging sector. Consumers will recognize this film throughout grocery stores, from candy aisles to ice cream freezers and snack displays,” remarked Pete Dias, Senior Director of Market, Product, and Application Development at PureCycle. “Brand owners have been actively searching for ways to include certified recycled content without sacrificing quality or aesthetics. Through our partnership with Innovia, we’ve proven that our PureFive® resin can meet those demands, affirming PureCycle’s role as a leading PCR supplier for the global flexible packaging landscape.”
During the trial, Innovia conducted thorough evaluations of the production process, analyzing how the resin performed throughout the full production sequence of cavitated BOPP. The PureFive Choice™ resin demonstrated processing capabilities comparable to the virgin polypropylene currently utilized in commercial films. Testing revealed that films incorporated with various percentages of PureFive Choice™ resin achieved similar mechanical and barrier properties to those made with virgin PP resin, both of which are essential for maintaining product integrity and ensuring efficient packaging line operations.
The PureFive Choice™ resin used by Innovia is a specially designed one-pellet solution optimized for film applications. The PureFive Choice™ portfolio aims to provide converters the ability to integrate post-consumer recycled polypropylene while maintaining the reliability and application performance typically associated with virgin materials. PureCycle’s resin is produced using a patented dissolution recycling method that eliminates color, odor, and contaminants from post-consumer polypropylene, resulting in a recycled resin applicable to a broad spectrum of end uses.
For further details, please visit www.purecycle.com.
