Food-safe recyclates from household lightweight packaging collections – Interzero breaks new ground

The European Packaging and Packaging Waste Regulation (PPWR) requires companies to use recycled raw materials in packaging in the future. However, the market currently lacks precisely recyclates suitable for contact-sensitive applications such as food and cosmetics. Interzero has now developed a process that enables food-grade and near-food-grade recyclates to be mechanically processed from material collected via Germany's lightweight packaging collection system (dual system "Gelber Sack“). To manufacture these materials, the circular economy service provider, which operates across Europe, is opening a new site in Dessau, Germany, and taking on a pioneering role.

 

 

The Packaging and Packaging Waste Regulation (PPWR) introduces binding minimum quotas for the use of recyclates in packaging. From 2030, plastic packaging for food or cosmetic products that is not made from PET must contain at least 10 per cent post-consumer recyclate (PCR), recycled raw materials derived from used packaging. From 2040, this will rise to 25 per cent. The challenge is that these volumes are not yet available on the market, while the requirements for producing such recyclates are demanding. Significant investment is needed in sorting and processing in order to meet regulatory requirements. Yet the recycling industry is under pressure due to high energy costs, volatile prices and currently subdued demand for recyclates.

 

“Despite the currently difficult market environment, Interzero is continuing to invest in mechanical recycling for tomorrow’s needs with our new site for the production of recyclates suitable for contact-sensitive applications. With this step, we are demonstrating how effective the circular economy can be and making a clear commitment to Europe’s raw material sovereignty,” says Jan Kroker, CEO of Interzero.

 

 

(PP recycling I Source: Interzero)

 

Input: household lightweight packaging waste – Output: mechanically recycled PP (mrPP) for high-quality applications

Over a period of more than five years, the engineering team led by Thomas Herkert worked intensively to develop the optimum sorting and recycling process for the polypropylene recyclable material stream (PP) from Germany’s lightweight packaging collection system (“Gelber Sack”). The feedstock for the new plant in Dessau comes from Interzero’s own lightweight packaging sorting facilities. In Dessau, the bales of recyclable material are first shredded and washed, then carefully re-sorted and processed. The resulting flakes are subsequently recycled into recyclates. The necessary decontamination is carried out on site together with a partner. The end product is a recyclate that is also suitable for applications with high-level requirements.

 

“In our product development work, we focused on creating a recycled raw material suitable for use in hot-fill applications, microwaveable products, or foods with a high fat or acid content,” explains Thomas Herkert, Head of Sorting & Processing at Interzero.

 

Pilot plant to produce 5,000 tonnes of mrPP granulate per year

All tests relating to the sorting and recycling process for the pilot plant, as well as initial tests for the use of the material in food packaging, have already been completed successfully. The pilot plant, initially designed for a production capacity of 5,000 tonnes of mrPP, is currently under construction. The approval procedure with the European Food Safety Authority (EFSA) for the use of the regranulates in food-grade, near-food-grade and cosmetic applications is now being initiated.

 

Moreover, the project is highly scalable. With the process developed by Interzero, a solution is now available for the largest proportional share of hard plastic materials in household collection streams. According to a 2024 packaging study by Pforzheim University, around 11 per cent of plastic packaging collected in Germany’s lightweight packaging “Gelber Sack”/ “Gelbe Tonne” is made up of PP.

 

“The PPWR is increasing the pressure to adapt regulations. A strong European circular economy now needs room to manoeuvre. In the end, what matters is how safe and functional the product is – regardless of the feedstock,” urges Interzero CEO Jan Kroker. “Achieving the goals of the PPWR will require strong technologies working together. For PP recycling, this means using mechanical and chemical recycling in a complementary way in order to keep as many recyclable materials in the loop as possible. The task now is to create the right framework conditions so that this technological know-how can be put to use,” Kroker adds.

 

 

About Interzero:

Interzero is one of the leading service providers in the field of closing product, material and logistics loops as well as an innovation leader in plastics recycling with the largest sorting capacity in Europe. Under the guiding principle of “zero waste solutions”, the company supports over 80,000 customers throughout Europe in the responsible handling of recyclable materials, thus helping them to improve their own sustainability performance and conserve primary resources. With about 2,000 employees, the company achieves a turnover of nearly one billion euros. According to Fraunhofer UMSICHT, Interzero’s recycling activities could save 1.04 million tonnes of greenhouse gases compared to primary production and 8.09 million tonnes of primary raw materials in 2024 alone. For further information, please visit www.interzero.com.