An Introduction to Recycled Polypropylene (rPP): A Sustainable Plastic Packaging Solution

As consumers become more environmentally conscious and environmental regulations increase, CPG companies must explore more sustainable materials to package the goods that they produce. This blog explores a promising recycled material that could pave the way for more sustainable plastic packaging for many food and household products – recycled polypropylene (rPP).

Polypropylene (PP) is one of the most widely used plastics in the world. However, like other plastics, traditional PP is derived from fossil fuels and can contribute to plastic pollution when not properly recycled. The urgency for sustainable packaging is apparent: most CPG companies, especially some large corporations, aim to use at least 25% recycled content in their packaging soon.

For instance:

• Coca-Cola has set a goal to use at least 50% recycled material in its packaging by 2030.
• Unilever plans to increase recycled plastic material content to 25% by 2025.

Recycled polypropylene (rPP) offers a more sustainable packaging material option for many CPG companies. If your CPG company is looking for alternative plastic packaging materials, read on to learn more about:

•  what rPP is,
• how it’s produced,
• and what its benefits and limitations are.

Polypropylene is a widely used thermoplastic polymer known for its durability, flexibility, and chemical and heat resistance. rPP is a recycled version of PP, meaning it’s more sustainable and environmentally friendly than its first-use counterpart.

rPP production involves reclaiming post-consumer waste and processing it into usable material through two primary methods: mechanical and chemical recycling. 

Mechanical recycling collects, sorts, cleans, and physically reprocesses polypropylene waste—washing, shredding, melting, and reforming it into new products.

Chemical recycling takes a different approach, breaking down plastic polymers into their basic chemical building blocks, allowing them to be rebuilt into new materials with properties similar to virgin plastic.

Polypropylene represents 16% of total plastic production and is the primary resin for food-grade packaging, yet it remains almost entirely unrecycled. Major consumer brands like Procter & Gamble rely heavily on PP, but the material's current lifecycle is fundamentally unsustainable.

In the US, recycling rates are dismal: only 8% of PP containers are recycled, compared to 28% for PET bottles. A mere 3% of polyolefin production comes from recycled materials. These numbers don't just represent a recycling challenge — they present a critical opportunity for rPP to revolutionize plastic sustainability.

Recycled polypropylene emerges as the clear solution to these systemic failures. By addressing the inherent limitations of traditional PP recycling, rPP offers a pathway to dramatically reduce waste, lower carbon emissions, and create a more circular plastics economy.

Millions of tons of plastic waste end up in landfills yearly, contributing to pollution and harming ecosystems. rPP gives discarded plastic a second life and diverts it from landfills into continuous use.

Producing virgin polypropylene requires significant energy and fossil fuels, contributing to high greenhouse gas emissions. However, the carbon reduction potential of rPP varies significantly by recycling method. While mechanical recycling shows promise for reducing emissions, chemical recycling may not be as effective. Companies should approach carbon reduction claims carefully, recognizing that not all recycling methods deliver equal environmental benefits.

A circular economy promotes sustainability by using materials for as long as possible through reuse and recycling. rPP prolongs the life cycle of polypropylene, and as more and more companies make pledges to increase the use of recycled content in their packaging, rPP is poised to become a more popular option. 

While rPP is a versatile and sustainable material choice, it has a few drawbacks. If you’re considering using rPP in your packaging, it’s important to be aware of these limitations to ensure your packaging is as good as it can be.

rPP struggles with variability. Depending on source materials, the material’s color, strength, and composition can differ dramatically. Mechanical recycling builds on this issue, degrading packaging properties over multiple cycles, affecting durability and performance.

In the U.S., both mechanically and chemically recycled polypropylene (rPP) must undergo FDA evaluation for use in food-contact applications. This is typically done through the "No Objection Letter" (NOL) process, which assesses the specific recycling process and its ability to produce material that is safe for food-contact use.

Manufacturers must demonstrate their recycling process consistently produces material that meets safety standards, including thorough cleaning, decontamination, and quality control measures to ensure the final product is safe for direct food contact.

Cost is a significant hurdle for rPP adoption. Virgin polypropylene often remains cheaper to produce, making it a more attractive option for many companies. Market prices for rPP fluctuate frequently due to its commodity nature, creating uncertainty for businesses considering a transition to recycled materials.

Many regions still lack the proper collecting and sorting infrastructure for polypropylene recycling, which can limit rPP’s availability in certain markets. The American Chemistry Council’s stark finding reveals that post-consumer PP recovery sits at less than 1%— the lowest rate among all plastics.

The fundamental problem lies in polypropylene’s versatility. The material is used in packaging, construction, automotive, sports, and other industries, with each industry presenting unique recycling challenges. Unlike more uniform plastics like PET, polypropylene demonstrates extreme sensitivity to input materials, requiring thorough sorting and processing techniques that current infrastructure cannot manage.

Despite the challenges, the future is bright for rPP. As processing technologies evolve and more companies commit to using recycled materials, rPP will continue to gain traction as a viable, sustainable plastic packaging material. The key to unlocking rPP's potential lies in infrastructure and legislation. By creating unified national standards, streamlining compliance processes, and aligning recycling technologies, consumer brands and packaging specialists can transform rPP from a promising concept to a game-changing solution for sustainability.

If your company is exploring sustainable plastic packaging options, get in touch with us and let's find the right material solution for your product.