Several partners from across the flexible food packaging supply chain have worked together to launch new, premium quality snack packaging that contains 50% recycled plastic and meets stringent food contact requirements. 

The new packaging was launched in the UK and Ireland for Sunbites, PepsiCo’s well-known snack brand, in late 2023. The packaging is made by recycling plastic waste into food grade packaging material. This is done using an advanced recycling process, a complementary approach to mechanical recycling, which enables the recycled materials to satisfy the demanding EU regulatory requirements for applications such as food contact packaging, contact sensitive and medical devices.

Brands and retailers use flexible film packaging to ensure food maintains its freshness and prevent food waste.

Several partners across the entire supply chain collaborated to enable the launch of this attractive new circular packaging:

GreenDot ensured the procurement and supply of post-consumer plastic packaging waste, which was converted into TACOIL (pyrolysis oil) using Plastic Energy’s technology.

INEOS Olefins & Polymers Europe used this pyrolysis oil as an alternative to traditional fossil feedstock to first produce recycled propylene, before turning this into virgin-quality recycled polypropylene resin at its plant in Lavera, France.

IRPLAST uses the new resin to turn existing plastic packaging designs into new packaging films that contain 50% of post-consumer recycled materials and meet the food contact performance requirements.

Amcor transformed these films into printed packaging that delivers the same technical performance for PepsiCo.

Using these new polypropylene films, PepsiCo launched the Sunbites packaging in the UK. The partnership is part of PepsiCo Positive (pep+), the company’s end-to-end transformation, which aims to eliminate virgin fossil-based plastic in crisp and chip bags in €ope by 2030.

The recycled polymer content is certified under the International Sustainability and Carbon Certification (ISCC PLUS) scheme, an independent third party who certify that it has been tracked through the production process using mass balance principles and that the claim being made is accurate.