The EU Packaging and Packaging Waste Regulation (PPWR), which entered into force in 2025, is profoundly changing food packaging rules. Companies must start now designing for recyclability, increasing recycled material content (PCR) and reducing unnecessary packaging. But sustainability and shelf life are not in contradiction: both can be achieved.
The PPWR and obligations for food companies
The EU PPWR (Packaging and Packaging Waste Regulation) sets progressive targets: all packaging must be recyclable by 2030, with increasing minimum PCR (Post-Consumer Recycled content) quotas for each material type. For Italian food manufacturers the most impactful obligations concern multi-layer plastic films, often not recyclable in current infrastructure.
- 100% recyclability by 2030 (design for recycling)
- Minimum PCR content: 10-30% depending on material and application
- Reduction of unnecessary packaging: mandatory essential design
- Recyclability labelling mandatory on every package
- Environmental product declaration (EPD) for large companies
Recyclable films for vacuum and MAP: where we stand
The main technical problem is that high-barrier films (PA/EVOH/PE) needed for vacuum and MAP are multi-layer structures not easily separable for recycling. The solution is mono-material: PE/PE or PP/PP coextruded films with different density layers that maintain necessary barrier while remaining in a single recyclable polymer family.
Mono-material PE films achieve OTR of 15-30 cm³/m²·24h, suitable for vacuum packaging of meat and cured meats with 30-60 day shelf life. For applications with higher barrier requirements (OTR < 5) the solution is EVOH coating on PE substrate, maintaining recyclability in the PE stream.
- PE/PE coex: recyclable PE stream, OTR 15-40 cm³/m²·24h
- PP/PP coex: recyclable PP stream, more rigid, for trays
- PE + EVOH coating: high barrier + PE recyclability
- PA/PE (traditional): not currently recyclable, in transition phase
- EVOH winding: bridge solution for recyclability with high barrier
Sustainable trays: from PS to rPET and paperboard
Expanded PS (polystyrene) trays are the most problematic for recyclability: they are not accepted in separate collection systems. The transition is to rPET (recycled PET), recyclable PP, CPET and paperboard with internal barrier. Paperboard trays with internal PE film are recyclable in the paper stream if PE weight is < 5% of total.
- rPET: recyclable PET stream, good OTR, FDA/EFSA approved for FCM
- Recyclable PP: rigid trays, recyclable PP stream
- CPET: recyclable + oven-resistant, for ready meals
- Paperboard + internal PE: recyclable if PE < 5% total weight
- Avoid expanded PS: not recyclable, target gradual phase-out under PPWR
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