Welcome back to the Crazy About Packaging podcast blog — your go-to place for no-fluff, real talk about packaging. In Episode 3, the C.A.P. Pack (Natalie, Mike, and Jonathan) take on the questions they hear most often from engineers, brand owners, and packaging pros about ICPG’s most talked-about material: XPP.
You may have heard us mention XPP before (okay, maybe more than just a few times), but this episode digs into the real questions people are asking behind the scenes at trade shows, during commercial calls, and in day-to-day conversations.
So whether you’re curious if your current FFS line can run it, wondering how it stacks up against PET, or just trying to figure out what XPP even is, this episode is for you.
Sneak Peek for Episode 3
You can watch the full episode above or listen on Spotify, Apple Podcasts, or on our website.
Want a sneak peek? Read on for some fast answers to the big XPP questions we explored. If you're not already on board the XPP train, you will be soon!
What is XPP, and how is it different?
Let’s start with the basics. XPP is ICPG’s custom-developed polypropylene (PP) material built specifically for form fill seal (FFS) packaging. While there’s no such thing as “regular” PP — because polypropylene itself is a highly versatile material — XPP was engineered to perform like polystyrene on existing FFS equipment while providing the sustainability and recyclability benefits of PP.
In short: It behaves like PS on the line but checks all the boxes that PS can’t.
Is it different from other polypropylenes I’ve tried before?
Yes. Very.
XPP is not mineral-filled. It’s not foamed. It can run on FFS equipment and maintains the snap-ability critical for multipack formats. It also has inherent barrier performance and low shrink, making it suitable for high-barrier applications without complicated coatings.
Can XPP run on my current form fill seal equipment?
Yes, with some tuning.
This is one of the most common questions ICPG gets — and for good reason. No one wants to overhaul an entire line for a new material. That’s why we’re so excited that XPP can run on PS-designed FFS lines with adjustments to optimize heating, sheet tension, and compression. This is the kind of process fine-tuning ICPG helps customers with every day.
Even better? Because of how XPP is formulated, processors typically don’t need to make heavy capital investments. The material is built to minimize disruption and maximize existing assets, which is why teams like ICPG’s stay involved in qualification and implementation.
Why choose XPP over PET?
PET may have been a front-runner for replacing PS, but when you start looking closer, the differences start to add up fast.
PET:
- Is 33% heavier than PP
- Wears down trim tools faster
- Often requires multi-station cutting systems
- Frequently uses coatings or laminations that make it non-recyclable
XPP:
- Is lightweight, cutting down material use and carbon impact
- Cuts cleanly, extending the life of tooling
- Delivers inherent barrier performance, often without EVOH
- Remains recyclable across opaque colors and multi-layer formats
And yes, XPP meets APR Design for Recyclability guidelines and avoids materials on the US Plastics Pact Problematic Materials List.
What are the key benefits of using XPP?
We like to keep it simple. Mike, Jonathan, and Natalie boiled it down like this:
- It works
- It’s sustainable
- It costs less
Those three pillars drive everything from packaging performance to supply chain impact. XPP supports applications from multipack dairy to hot fill, aseptic, and refrigerated or shelf-stable goods. It’s suitable for converters and brands looking to close the gap in their recyclable packaging portfolio, especially those still stuck using polystyrene for just one or two SKUs.
Need more proof? XPP offers:
- Versatile application compatibility (FFS, thermoforming, hot fill, aseptic, and more)
- Excellent organoleptics (taste and odor neutral)
- Superior moisture protection
- Opaque and transparent options that remain recyclable
And while PCR (post-consumer recycled) polypropylene for extrusion is still a maturing market, ICPG is already incorporating PCR into XPP and expects PCR versions to be commercially available in 2026.
Where is XPP made, and how do I get it?
ICPG manufactures XPP in Hamlet, North Carolina, and currently ships globally. But sustainability isn’t just about material choice. It’s also about how far you have to move it.
To support that, ICPG is licensing XPP production technology to other extruders around the world, including competitors and regional suppliers. They’re even open to licensing directly to brands. It’s a collaborative, global approach designed to scale access while supporting local supply chain needs.
The Origin Story: From Trial to Unicorn
The XPP story started over 15 years ago with a need to move away from polystyrene, back when sustainability pressures were growing but technical options were slim. After years of R&D, a resin trial meant to solve a barrier challenge instead led to something more.
When the ICPG team snapped a scored XPP sheet across the web and it broke cleanly, they realized they’d created something special. Something PS-like, but recyclable. Something that cut cleanly, processed smoothly, and met the market's technical demands.
As Jonathan put it, “We were looking for a unicorn, and we found one.”
Is XPP commercial today?
Yes. And you already know the brand.
You can now find XPP in Dunkaroos multipack snack trays made by General Mills. This iconic turquoise snack pack transitioned from an unrecyclable PET-based material to ICPG’s XPP, resulting in improved sustainability, reduced costs, and consistent brand quality.
Want to know how they did it? Download the full Dunkaroos Case Study.
One Material. Endless Possibilities.
XPP isn’t a one-hit wonder (unless you want it to be!). It’s the one material that can handle multipacks, hot fill, aseptic, shelf-stable, refrigerated, and more. If you’re looking to replace polystyrene in FFS or simply want a recyclable alternative that won’t break your tooling (or your budget), XPP should be at the top of your list.
And if you’re still figuring out how it might fit into your application, reach out. The team at ICPG is ready to help you evaluate, test, and transition.
Catch the full episode on Spotify, Apple Podcasts, or on our website.
Leave a comment, subscribe, or message us directly, because if there’s one thing we love to talk about, it’s packaging. Especially XPP.
