GERMANY – INEOS Styrolution, a global leader in styrenics, has unveiled an innovative yogurt cup made entirely from 100% food-grade recycled polystyrene.
This breakthrough, achieved in collaboration with multiple partners across the value chain, marks a significant step forward in sustainable packaging solutions.
The process of mechanically recycling polystyrene involves several stages, including advanced sorting techniques such as deep NIR sorting with object recognition, hot washing, flake sorting, melt filtration, and pelletizing.
At the heart of this innovation is INEOS Styrolution’s proprietary “super clean process,” recognized as a novel technology under EU Regulation 2022/1616.
This process ensures the recyclates meet food-contact quality standards, previously achieved only with PET bottle recyclates.
The resulting material retains the same physical properties as conventionally produced polystyrene, providing a perfect circular solution with a significantly reduced environmental footprint.
Consumer acceptance and testing
In spring 2024, INEOS Styrolution collaborated with Unternehmensgruppe Theo Müller, one of Germany’s leading dairy producers, to test consumer acceptance of the recycled polystyrene yogurt cups.
Hundreds of cups were filled and distributed to volunteers in an INEOS canteen. The results were overwhelmingly positive, with 90% of participants indicating they would purchase products in recycled cups.
Feedback also revealed that consumers were open to aesthetic changes, such as cups in colors other than plain white.
The innovation was showcased at the Dresdner Verpackungstage (December 5–6, 2024) by Lena Lembach, Senior Packaging Development at Unternehmensgruppe Theo Müller, and Dr. Frank Eisenträger, ECO & Market Development Manager at INEOS Styrolution.
Dr. Eisenträger highlighted the significance of this development, “Polystyrene has now entered the champions league of recycled food-contact materials. This will enable producers to meet the stringent requirements of the new EU Packaging and Packaging Waste Regulation (PPWR).”
Lena Lembach added, “This achievement represents a major milestone on the path to perfect circularity for polystyrene cups. It also supports our efforts to meet PPWR requirements and achieve CO2 reduction goals.”
This innovation demonstrates the potential of polystyrene as a sustainable packaging material, offering manufacturers a viable solution to meet regulatory demands and consumer expectations.
With advancements like this, INEOS Styrolution is paving the way for more circular and environmentally responsible packaging in the food industry.
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