Why the Yoghurt Pot is a Symbol of the Challenge Facing the Packaging Industry

Alongside cucumbers packaged in plastic film, the yoghurt pot is one of the most frequently used examples of the complexity of the issue of sustainable packaging. If a pot is made of plastic and paper, the question arises as to whether consumers will remove the paper sleeve, and whether the packaging components will end up in the right bins. In a practical test, consulting agency Berndt + Partner found that the majority of yoghurt packaging is already equipped with seals and disposal instructions. The switch to mono-materials is increasingly being implemented. The experts only recognize deficits in design, presentation at the point of sale, and the design of secondary packaging. In the packaging test, Landliebe yoghurt in a molded pot was rated as exemplary.

PPWR Puts Pressure on

In future, manufacturers of dairy products such as yoghurt, cheese spreads, pudding, cream, and cream cheese are to use more sustainable packaging. The European packaging regulation PPWR sets the direction. From 2030, plastic food packaging must contain a minimum percentage of recycled material. Packaging manufacturer Alpla explains that the problem is that “there is no approved recycling material from the mechanical recycling process for yoghurt pots made of PP or PS for contact with food. Small quantities are only available via chemical recycling, which is far more costly and energy-intensive. Too little for widespread use.”

Alpla is focusing on the “all-rounder” PET (polyethylene terephthalate). In collaboration with machine manufacturer Engel, mold maker Brink, label producer iPB Printing, and joint venture partner Intopack, Alpla has now developed thin-walled PET plastic cups with recycled material for the first time. The single-stage injection molding process enables fully recyclable packaging made from up to 100 percent rPET. “This makes it easy to achieve the 30 percent recycled material content required by the PPWR for PET,” says Alpla. The solution is set to go into series production starting in the 4th quarter of 2025.

Recycled PET (rPET) is PET that has already been used, recycled, and reused at least once. Today, food-grade r-PET is obtained almost exclusively from bottle streams. Is there enough rPET for everyone? No one can make a valid statement. “However, we are currently assuming that the quantities of recyclate available on the market by 2030 will not be sufficient to account for 30 per cent of all food contact materials,” explains DMK Deutsches Milchkontor GmbH in response to an enquiry from FACHPACK360°. 

DMK explains further: “Of course, it is also possible to mechanically re-granulate and recycle PS or PP and produce numerous good packaging materials from them. There are now mechanical, solvent-based (rPS) or chemical (rPP) processes approved for food contact for the production of both rPS and rPP. However, both materials (rPP and rPP) are currently only available on the market in very small quantities and are, therefore, very cost-intensive.” Which is why the DMK Group is involved in projects on various recycling technologies via the IVLV, but is also looking into the use of RPS.

Tomra, a manufacturer of reverse vending machines, among other things, explains that the demand for food-grade rPET for bottle production is outstripping supply. An increase in the recycling capacity of this quality (for example through advanced mechanical recycling) and the supply of collected PET bottles of sufficient quality are required to fulfil this capacity.

Modesto Marcus Pesavento, Managing Director of Eproplast GmbH, recommends a maximum proportion of 50 per cent rPET because a balanced mix of new PET and rPET offers “the optimum balance between sustainability, functionality, and appearance.” The complete use of rPET is also not ideal from a circular economy perspective. “It is currently unproblematic, as there is sufficient rPET available on the market. However, if everyone were to use 100 per cent rPET exclusively, the circular system could be impaired in the long term.”

In January, Fernholz Verpackungen received authorization from the EU to process recycled PET for direct food contact. W. u. H. Fernholz GmbH & Co. KG is a producer of films and plastic packaging based in Meinerzhagen and Schkopau. According to its own estimates, the company is now one of around 250 companies in Europe and around 25 companies in Germany that have received this authorization.

Hot-washed flakes are an important component in the plastic recycling process. They undergo a multi-stage cleaning process to remove impurities such as adhesive and beverage residues. However, this process alone is not sufficient for the flakes to be used in the production of films and packaging with food contact. Decontamination using special heating processes is also required. 

With this approval, Fernholz Verpackungen is now authorized to operate a recycling plant at its site in Meinerzhagen that processes hot-washed flakes into flakes for the production of films and packaging for direct food contact. “This EU authorization is a milestone for our company and confirms our sustainable innovation course,” explains Michael Roth, Managing Director of Fernholz. “We focus on resource-conserving production and want to actively contribute to the further development of the circular economy in the packaging industry.”

Greiner Packaging is also focusing on the growing demand for r-PET and purchased its first PET recycling plant in Serbia in the autumn of 2022. Since then, the company has been offering r-PET flakes in various purity levels under the name Greiner Recycling, which are available to Greiner Packaging customers.

By Anna Ntemiris, Editor