And while environmental concerns around plastic use are well known, this latest research argues that recyclability is more important than simply reducing plastic content. Additionally, food packaging has a direct correlation to food wastage. Waste and Resources Action Programme (WRAP) estimates total food waste in the UK in 2021 at 10.7 million tonnes. According to the UNEP Food Waste Index Report, 60% of food waste happens at household level with food spoilage due to poor storage being a key cause.
Choosing the Right Material for Food Packaging
Neil Shackleton, packaging expert and founder of sustainability consultant Medoola says:
“Rather than setting goals to minimise plastic content, the key objective is to have the right material for the right product in the right supply chain. There is no single one size fits all in terms of materials. For food like fruits and meats, rigid and semi rigid plastic packaging can often be the more sustainable option than alternatives as it increases the products’ shelf life along with the ability of being easily recyclable.”
Comparing Recyclability and Carbon Footprint
Valpak’s PackFlow Refresh 2023 Report suggests 63% of rigid consumer waste plastic packaging was recycled in the UK, whereas the recycling rates for composite fibre based packaging (excluding liquid paper cartons) are close to 0%.
The Green Alliance’s Plastic Promises Report highlights the prevalent misconception around plastic and the decision by major supermarkets and FMCG companies across the country to switch away from plastic. This is mainly fuelled by consumer pressures and often made without considering the environmental impact of the substitute materials chosen, or whether or not there is adequate collection and treatment infrastructure in place for them.
The report interviewed representatives from five of the UK’s largest supermarket chains. Respondents described ‘a lot of pressure to move to [alternative packaging] which isn’t necessarily better from an environmental point of view’ and understood that switching from plastic to other materials ‘may, in some cases, be increasing the carbon footprint’.
Cradle-to-Gate Analysis: rPET vs Laminated Trays
The comparative life cycle based cradle to gate analysis assessed the environmental impact of two common types of food packaging:
● Fully recyclable rigid plastic tray, made from 85% recycled PET (rPET)
● A laminated paperboard tray, with 80% less plastic content but which is made from virgin materials.
The findings indicate that while the laminated paperboard tray uses less plastic, it is made from virgin paperboard and virgin low-density polyethylene (LDPE) flexible plastic lining. This makes it difficult to recycle and leads to higher carbon emissions due to the extraction and processing of the required raw materials.
In contrast, the tray made from rPET (recycled PET plastic) – a material created by processing post-consumer plastic waste – is fully recyclable and reduces waste and reliance on virgin materials.
Environmental Benefits of rPET Food Packaging
Key Findings from the Study:
● Recyclable plastic trays made from rPET produce notably less CO2 emissions than non-recyclable laminated trays.
● Paperboard trays require complex manufacturing involving energy-intensive pulping and chemical processing.
● Plastic-lined paperboard trays typically end up in landfill or incineration, further increasing emissions.
● Recycled PET trays can be fully reclaimed, reducing environmental impact and plastic waste.
These results highlight rPET's effectiveness in reducing greenhouse gas emissions, aligning with global sustainability goals and the growing demand for eco-friendly food packaging solutions. As consumer and regulatory pressure for sustainable solutions intensifies, commonly recycled plastics such as rPET can present the most effective and viable solution.
Industry Support for Circular Packaging Solutions
The lead researcher explains: “This research suggests that simply reducing plastic use is not enough – consideration of recycled content, recyclability and carbon emissions is crucial. Our study argues that rigid plastics designed for recycling are a far more sustainable option than laminated alternatives in food packaging that cannot be processed through standard recycling systems.”
The research highlights the importance of a circular economy in packaging design. Rather than focusing solely on reducing plastic content, manufacturers and consumers should consider whether a product can be effectively recycled and reduce reliance on virgin resources.
Industry Experts Endorse Recyclable Plastic Trays
These findings are reinforced by a consortium comprising several businesses in the food packaging industry. The consortium called RPETS urges brands, retailers, and policymakers to prioritise packaging that can be recycled, rather than those that simply reduce plastic content but end up in landfill. The group includes sustainable packaging specialists – iPac Packaging Innovations and Pakway – both accredited by BRCGS – global standard for food safety and packaging.
Jonny Catto, Managing Director of iPac Packaging Innovations, said: “There’s a misconception that if an item such as packaging is made of plastic, then it is unsustainable, but this research makes it irrefutably clear – recyclable plastic trays like rPET are part of the solution, not the problem. The real issue is materials that are very difficult to recycle, like plastic-coated paper trays being mistaken as a more sustainably viable option. We need to shift the conversation towards better recycling infrastructure and consumer education.
“By demonstrating the significant carbon savings achievable with rPET, this research provides a strong case for businesses to seriously reconsider material substitutions that simply aim to ‘reduce plastic.’”
Jeff Brunskill, Managing Director at Pakway added: “This study should serve as a wake-up call for the industry. We need solutions that actually work in real-world recycling systems – not just packaging that looks sustainable on the surface.”
