The global demand for plastic waste reduction remains a pervasive industry concern, as major brands pledge to transition to more sustainable packaging solutions and make commitments to significantly reduce the percentage of virgin material used.
Anyone working in the food packaging industry understands that this is far more complicated undertaking than it may seem. - Redevelopment requires packaging to be more sustainable, while continuing to deliver on processing efficiency, polypropylene barrier performance, convenience, quality, and cost.
Why Material Selection Matters
When examining ways to develop or redesign more sustainable packaging solutions for food applications, an easy place to start is by evaluating the materials used and identifying alternatives that deliver stronger performance across all metrics — including recyclability and polypropylene barrier protection.
Material structures used for shelf-stable barrier products often rely on complex multi-material compositions. While effective at maintaining food safety and quality, these structures are not always the most sustainable or recyclable option.
In contrast, polypropylene barrier structures simplify material composition while maintaining high-performance protection.
The Advantage of Polypropylene Barrier Structure
As the global demand for packaging solutions with improved sustainability and recyclability continues to take precedent, mono-material packaging structures have emerged as a leading solution made possible through innovations in materials such as polypropylene that enhance oxygen and moisture resistance.
Polypropylene is one of the most versatile materials used in the industry today. Expanded production capacity in the U.S. has created new opportunities for innovation in polypropylene barrier applications, enabling more sustainable and high-performing food packaging solutions. Both the inherent characteristics of polypropylene and advancements in material science make it an excellent material for brands seeking to develop next-generation polypropylene barrier packaging.
Sustainability Performance of Polypropylene Barrier Structures
Below are three reasons why ICPG's polypropylene solutions result in a more sustainable choice for extended shelf-life rigid food packaging applications.
1. Polypropylene Barrier Structures Promote Simplification and Enhanced Recyclability
All plastics are recyclable, right? Not quite.
Parts made from 100% polypropylene are fully recyclable using the Resin ID Code (RIC) #5. Similarly, coextruded barrier PP/EVOH/PP structures made with at least 90% polypropylene may also be recycled using RIC #5. This is because the incorporation of EVOH at 10% or lower is considered an acceptable threshold for reprocessing performance.
For high barrier applications that require the inclusion of EVOH to meet shelf-life requirements, containers may continue to be recycled through the PP rigid recycling stream as long as they maintain the proper ratio of PP to EVOH. In comparison, alternate multi-material structures often require RIC #7 (Other), creating recycling challenges and negative brand perception.
But what if the application does not require a high percentage of EVOH in order to achieve desired shelf-life expectations? Materials such as ICPG's XPP™ Enhanced Barrier Polypropylene offer enhanced oxygen and moisture barrier enhancement up to 80% — before the incorporation of EVOH — allowing brands to significantly reduce EVOH content or eliminate it entirely, depending on application.
This XPP™ polypropylene barrier technology enables simplified, 100% recyclable packaging while maintaining required barrier performance, functionality, and processing efficiency.
2. Polypropylene Barrier Innovation Supports Virgin Plastic Reduction and Circular Economy Goals
Innovation in polypropylene extends beyond performance enhancement. Significant advancements in post-consumer recycled (PCR) polypropylene purification processes are transforming material recovery.
Advanced recycling technologies enable PCR PP to return to a near-virgin state, delivering comparable performance, properties, and processing attributes to virgin homopolymer PP. The purification process removes colorants and contaminants, producing high-quality recycled resin suitable for polypropylene barrier structures.
Incorporating PCR materials into multi-layer polypropylene barrier packaging allows brand owners to meet sustainability commitments by reducing virgin plastic usage. In addition, ICPG’s multi-layer coextrusion capabilities enable encapsulation of post-industrial recycled materials into extended shelf-life polypropylene barrier applications, increasing recycled content without compromising performance.
These advancements directly support circular economy objectives while maintaining the integrity required for rigid food packaging.
3. Polypropylene Barrier Materials Deliver a Lower Carbon Footprint
Compared to other materials typically used in food packaging, polypropylene has the lowest density and is the lightest, resulting in a number of downstream energy savings and a lower environmental impact.
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- Reduced CO2 equivalents by weight
- Less solid waste by weight
- Lower fuel consumption & emissions
The lower density improves material yield during thermoforming, allowing manufacturers to produce more parts from the same amount of material — approximately 30% higher yield compared to PET and 13% higher yield compared to PS (application dependent).
When combined with reduced EVOH requirements enabled by polypropylene barrier technology, brands can pursue downgauging and lightweighting strategies that significantly decrease plastic consumption per unit.
Ready to Advance the Sustainability and Performance of Your Packaging?
ICPG combines advanced material science expertise with precision coextrusion technology to engineer high-performance polypropylene barrier solutions for extended shelf-life rigid food packaging. Our structures are designed to enhance recyclability, reduce virgin plastic usage, and deliver consistent oxygen and moisture protection without compromising processing efficiency.
Download the XPP™ Polypropylene Barrier Product Sheet or connect with our team to explore application-specific solutions.
