Emerald Packaging removes 1M pounds of virgin plastic from supply chain through PCR shift

USA – US-based flexible packaging manufacturer Emerald Packaging has replaced more than one million pounds of virgin polyethylene (PE) with post-consumer recycled (PCR) material in 2025, marking one of the company’s most significant sustainability milestones to date.

The move aligns with growing demand from major retailers, growers and distributors for packaging solutions that reduce environmental impact while maintaining performance and food safety standards.

Kevin Kelly, CEO of Emerald Packaging, highlighted the achievement as a testament to both innovation and industry collaboration.

“This milestone reflects Emerald Packaging’s commitment to the environment and our technical ability to deliver high-quality packaging while reducing the reliance on virgin plastics,” he said.

Kelly added that the company’s partnerships across the value chain have been essential in scaling PCR adoption.

“We’ve worked closely with our supply chain partners and customers to make PCR a viable and scalable part of our product offerings for those who are seeking sustainable options that meet performance standards without compromising environmental values.”

A key example is the October 2024 partnership with Idaho Package, Wada Farms and Walmart, which introduced the first 30% food-contact PCR bag for potatoes.

The innovation demonstrated that recycled content could meet stringent food-contact safety and performance requirements.

A similar collaboration with D’Arrigo Bros. of California led to PCR bags being adopted across its full product line, including romaine lettuce hearts and iceberg lettuce.

According to Emerald Packaging, the 30% PCR bags have already eliminated more than 600,000 pounds of virgin plastic from the produce sector alone.

The company says that integrating PCR materials contributes to landfill diversion and reduces emissions associated with virgin plastic production.

Emerald Packaging, currently the largest manufacturer of fresh-produce plastic packaging in the US, has also played a notable role in shaping California’s evolving recycling legislation.

The firm has been a vocal advocate for strengthening recycling infrastructure, advancing policies that encourage circularity, and setting enforceable recycled-content standards for packaging.

The announcement comes amid wider momentum across the North American packaging industry.

In 2025, major brands including General Mills, Fresh Express and Driscoll’s reported increased use of PCR in flexible and rigid packaging, driven by retailer mandates and state-level regulations.

California’s SB 54, which requires significant reductions in single-use plastics and scaled PCR incorporation by 2030, continues to influence packaging decisions nationwide.

Meanwhile, suppliers of PCR resin are expanding capacity in response to rising demand, though challenges persist around material availability, quality consistency and cost competitiveness.

Emerald Packaging says it will continue expanding PCR integration across product lines as supply, technology and regulatory frameworks evolve.

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