Coexpan partners Eslava to launch decontamination tech for recycled polystyrene in food packaging

SPAIN- Coexpan, a rigid packaging specialist under the Lantero Group, has partnered with Eslava to introduce a decontamination process that recycles post-consumer polystyrene into material suitable for food contact. 

The effort focuses on items like yoghurt pots, where 350,000 metric tons of polystyrene went into production last year.

According to details from the companies, the process keeps used packaging materials in a closed loop for food-grade applications. 

This setup supports ongoing reuse in the sector without mixing with non-food waste streams.

The technology relies on mechanical recycling methods, which generate a smaller carbon footprint than alternatives like chemical breakdown. 

Right now, the system sits in an advanced testing stage, where it transforms discarded polystyrene into clean raw inputs for new containers.

Eslava handles the separation and purification steps, drawing on artificial intelligence to ensure a steady flow of quality materials. 

The output meets top regulatory requirements for purity and security in food use. Eslava also supplies full traceability and quality certificates to back the recycled batch integrity.

Sergio de Freitas, CEO of Coexpan, said in a statement: “This project shows how collaboration and tech can deliver workable fixes for sustainability issues.”

“We take pride in closing the polystyrene loop while maintaining food safety and production speed.”

In parallel, the recycled material enters manufacturing lines for yoghurt and similar dairy products. 

Initial runs target small-scale integration, with plans to expand based on validation results. The partnership draws on Eslava’s long experience in waste handling across Spain and France.

David Eslava, CEO of Eslava, noted that years of development with regional management bodies have shaped the approach. 

He added that mechanical recycling proves reliable for safe, efficient material recovery.

This move comes amid growing efforts in polystyrene recovery. For instance, Ineos Styrolution rolled out 100% food-grade recycled polystyrene for yoghurt cups in December 2024. 

That product cut carbon emissions by over 170% versus fossil-based versions. Separately, in July 2025, Ineos Styrolution debuted recycled polystyrene sour cream cups that won a German Packaging Award for recycled content.

Coexpan and Eslava aim to scale the tech for broader dairy packaging needs by early next year. The process starts with collecting used pots from consumer streams, then applies decontamination to strip contaminants. 

Final pellets feed into molding for fresh pots, completing one cycle.

Eslava’s AI tools scan incoming waste for consistency, flagging impurities early. This precision helps avoid quality dips in the recycled output. 

Coexpan integrates the material at rates up to 30% in initial blends, with tests showing no impact on container strength or barrier properties.

The collaboration builds on Spain’s push for waste reduction targets. Last year, the country processed over 1.2 million tons of plastic packaging overall, with polystyrene making up a key slice. 

By reusing it locally, the partners cut transport emissions tied to virgin resin imports.

Freitas highlighted the efficiency gains in production lines. Operators report faster setup times with the recycled inputs, matching virgin material performance. 

Eslava’s team monitors each batch for microbial safety, essential for dairy applications.

As validation wraps up, the companies plan pilot runs with major yoghurt brands. Success here could double recycled content shares in their portfolios within two years. 

The tech also adapts to other polystyrene items, like deli trays, expanding its reach.

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