LyondellBasell (LYB) and Mondelez International have introduced new flexible packaging for Marabou chocolate bars containing 75% recycled plastic.

 

This marks a significant step toward circular food packaging using chemically recycled post-consumer plastic waste.

 

The new wrapper is made using LYB's CirculenRevive polymers, produced from hard-to-recycle mixed plastic waste through an ISCC PLUS-certified mass balance approach. The project also brings together packaging manufacturer Amcor, film producer Taghleef Industries and other partners across the plastics value chain.

 

The launch demonstrates how chemically recycled plastics can be transformed into food-grade packaging while helping brand owners meet growing recycled-content targets and anticipated European regulatory requirements.

 

"Our collaboration with Mondelez illustrates our shared vision for the future and highlights our ability to provide innovative, high-quality circular solutions tailored to demanding specifications,” said Yvonne van der Laan, executive vice president, Sustainable Solutions and Technology Business, LYB. 

 

“We’re committed to making circular and low carbon solutions work for businesses while creating solutions for everyday sustainable living.”

 

LYB said future polymers for Marabou packaging are expected to come from MoReTec-1, its first commercial-scale catalytic chemical recycling plant under construction in Wesseling, Germany.

 

Once operational, the facility is designed to process 50,000 metric tons of recycled feedstock annually for use in LYB's existing production assets, expanding the company's supply of recycled polymers. 

 

Mixed plastic waste will be processed by Source One Plastics, LYB's joint venture in Eicklingen, Germany, before being supplied to the recycling plant. Until then, LYB will continue sourcing recycled feedstock from third-party pyrolysis oil producers.

 

“This collaboration demonstrates how LYB can connect chemical recycling innovation with the scale and reach of our existing production network,” said LYB CEO Peter Vanacker. 

 

“As we advance MoReTec-1, we expect the facility to support future polymer supply for Marabou packaging and strengthen our ability to convert hard-to-recycle plastic waste into circular feedstocks for our existing assets. This integrated approach positions LYB to deliver value while advancing our circular and low carbon strategy.”

 

The packaging solution was developed through collaboration across the plastics value chain, with LYB supplying recycled polymers, Taghleef Industries producing the base film and Amcor converting the material into finished flexible packaging for Mondelez.

 

“Looking ahead, our ambition is to increase the use of recycled plastic in our packaging materials, and we’re proud to collaborate with multiple value chain players, including LYB and other industry leaders, on this journey,” said Packaging Sustainability Manager at Mondelez International, Richard Akkermans. 

 

“For consumers, the message is simple: plastic packaging can be recycled and allocated back into new food packaging. This initiative shows what becomes possible when brand owners, recyclers, packaging material producers and converters work together to turn circular ambition into commercial reality.”