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rPET Trays: Cutting Carbon, Costs, and Waste in Food Packaging

AVI Global Plast rPET trays, highlighting their recyclable, low-emission design as a true sustainable alternative to greenwashed packaging options.

Is Your “Green” Packaging Truly Sustainable?

Choosing sustainable packaging for your food business can feel like a daunting task—especially when so-called “eco-friendly” options fall short. A study by Viscotec reveals a game-changer: recycled PET (rPET trays), made from recycled PET, have the lowest carbon footprint compared to cardboard/plastic combinations, despite containing plastic. With over 10 million tonnes of food waste piling up annually in the UK (WRAP, 2021/22) and billions in global losses from non-recyclable materials (Eurostat, 2024), rPET trays offer a smarter path. They’re cost-effective, compliant, and built for a future where sustainability drives success.

The Greenwashing Trap: Why “Less Plastic” Fails

You’ve seen the buzzwords: “plastic-free” or “80% biodegradable.” But here’s the truth—those alternatives might not be as green as they seem. The Green Alliance’s 2020 Plastic Promises report found that five major UK supermarkets swapped plastic for options that “don’t always deliver” on sustainability. Why? Many alternatives, like laminated paperboard, can’t be recycled and take more energy to produce. Meanwhile, food waste—responsible for 8–10% of global emissions (UNEP, 2024)—spikes when packaging fails. In the UK, 60% of that over 10 million tonnes of waste happens at home (UNEP, 2024), often due to flimsy trays. rPET trays are different: recyclable, effective, and durable, designed to keep food fresher longer.

Why rPET Trays Stand Out

What makes rPET trays special? They’re built from 85% recycled PET, turning waste into something useful. Unlike energy-hungry paperboard or tricky-to-compost bioplastics, rPET trays are recyclable and practical. They align with SDG 12 (Responsible Consumption) by reducing waste and keeping food fresh longer—making them a win for businesses seeking sustainability without compromise.

Chart comparing rPET trays, laminated paperboard, and bioplastic trays, showing rPET’s superior recyclability and lower carbon footprint for sustainable food packaging
rPET vs. Laminated vs. Bioplastic Trays

rPET vs. Others: The Numbers Don’t Lie

Revolutionizing sustainable food packaging, rPET trays lead the charge with unmatched environmental and economic benefits. They outperform alternatives in every key metric, empowering businesses to achieve sustainability without sacrifice:

Packaging Type Recycled Content Recycling Rate (UK) CO2 Emissions
rPET Trays 85% 55% (WRAP 2023) Lowest carbon footprint
Laminated Paperboard 0%

(Virgin materials)

 ~0% Higher than rPET
Bioplastic Trays 0% (Plant-based) 10% (Composting rate) Higher than rPET

What This Means:

  • Lower Emissions: rPET trays outperform cardboard/plastic combinations in carbon emissions.
  • Better Recycling: 55% of plastic packaging is recycled in the UK, with rigid plastics like rPET trays achieving higher rates (WRAP 2023).
  • Shelf-Life Advantage: rPET extends food freshness by up to 14 days, addressing the UK’s over 10 million tonnes of annual food waste (WRAP 2021/22).
AVI Global Plast rPET trays, showcasing their recyclable design as a sustainable solution to greenwashing in food packaging.
Exposing Greenwashing with rPET Trays

Cradle-to-Gate Analysis: rPET vs Laminated Paperboard vs Bioplastic Trays

Choosing the right packaging isn’t just about meeting today’s demands—it’s about building a sustainable future. A comparative life cycle cradle-to-gate analysis reveals why recycled PET (rPET) trays are a better for environmentally conscious businesses. This study evaluated three types of food packaging:

  • Fully recyclable rigid plastic tray, made with 85% recycled PET (rPET), transforming post-consumer waste into a practical solution.
  • Laminated paperboard tray, with 80% less plastic but using virgin materials, challenging sustainability.
  • Bioplastic tray, made from renewable PLA, biodegradable under specific conditions but with variable impact.

The findings are clear: while laminated paperboard trays may appear eco-friendly with their reduced plastic content, they fall short in practice. Made from virgin paperboard and virgin low-density polyethylene (LDPE) lining, these trays are notoriously difficult to recycle, with a near-0% rate for composite fibre-based packaging (excluding liquid cartons) (Valpak 2023). Their production drives up carbon emissions due to raw material extraction. The other alternative ie Bioplastic trays, are often PLA-based, offer renewable sourcing but require industrial composting and may have higher land and water impacts (MDPI 2022).

In contrast, rPET trays shine as a forward-thinking choice. Created from 85% recycled PET, they’re fully recyclable, with a 55% recycling rate for UK plastic packaging (WRAP 2023). They deliver significantly lower CO2 emissions than laminated trays. For businesses striving to balance sustainability and practicality, rPET trays offer a proven, eco-friendly solution that aligns with your goals and paves the way for a greener tomorrow.

Chart comparing rPET trays, laminated paperboard, and bioplastic trays, showing rPET’s superior recyclability and lower carbon footprint for sustainable food packaging.

Environmental Benefits of rPET Food Packaging

Engineered for a greener future, rPET trays combine innovation and practicality to help businesses meet sustainability goals without compromise. Here’s why they lead the way:

  • Reduced Emissions: rPET trays emit significantly less CO2 than laminated paperboard and bioplastics, with 85% recycled PET cutting virgin material needs. Recycled PET reduces emissions by up to 79% vs. virgin PET also. (Green Alliance 2020).
  • Lower Waste: Fully recyclable, rPET trays reduce landfill and incineration vs. paperboard’s near-0% recycling rate (Valpak 2023).
  • Energy Efficiency: rPET uses existing recycling systems, unlike paperboard’s energy-intensive pulping or bioplastics’ complex processing (MDPI 2022).
  • Food Waste Reduction: rPET’s 5–14 day shelf-life extension tackles 54% of UK household food waste (WRAP 2021/22).

These benefits align with global sustainability goals, offering businesses an eco-friendly solution that prioritizes recycled content, recyclability, and a circular economy to meet rising demands.

The Future: rPET and Beyond

By increasing recycled content, the UK has cut plastic packaging emissions by 10.5% since 2018 (WRAP 2023), paving the way for a net-zero industry. Despite supply challenges for recycled materials (Eurostat 2024), strategic partnerships ensure scalability. Imagine a world where packaging powers sustainability—that’s the rPET revolution.

Partner with AVI for Sustainable Success

rPET trays are sustainable, affordable, and future-ready, and at AVI Global Plast, we make switching to them seamless. From our Daman plant, we produce 24,000 tonnes of rPET yearly, using ethically sourced recycled flakes backed by 12+ International certifications that ensure top-tier quality and sustainability. We go beyond supplying trays—we partner with you to solve your toughest packaging challenges, offering expert guidance for businesses with limited expertise or complex supply chains.

Worried about costs? Studies show that rPET is cost-effective over alternatives. Concerned about compliance? We’ve got you covered. Contact us at info@avigloplast.com or +91 022-68559300 to tackle your packaging challenges—whether you’re a small deli or a global supplier. What’s your packaging story? Share below!

FAQs

  • What is rPET packaging, and why is it sustainable?
    rPET (recycled polyethylene terephthalate) packaging is made from 85% recycled PET, like plastic bottles, reducing the need for virgin materials. It’s fully recyclable, has a 55% recycling rate in the UK (WRAP 2023), and emits up to 79% less CO2 than virgin PET (Green Alliance 2020). Its durability also extends food shelf life by 5–14 days, cutting food waste, which accounts for 8–10% of global emissions (UNEP 2024).
  • How does rPET compare to biodegradable or plastic-free packaging?
    rPET trays outperform laminated paperboard and bioplastics in sustainability. Laminated paperboard, often non-recyclable (near-0% recycling rate, Valpak 2023), and bioplastics, with low composting rates (10%, WRAP 2023), have higher carbon footprints and environmental impacts. rPET’s high recycled content and recyclability make it a lower-emission, practical choice for eco-conscious businesses.
  • Can rPET packaging help reduce food waste?
    Yes, rPET trays extend food freshness by up to 14 days, addressing the UK’s over 10 million tonnes of annual food waste, 54% of which occurs at home (WRAP 2021/22). By keeping food fresher longer, rPET supports SDG 12 (Responsible Consumption) and reduces the 8–10% of global emissions linked to food waste (UNEP 2024).
  • Is rPET packaging cost-effective for businesses?
    rPET trays are cost-competitive compared to laminated paperboard and bioplastics, offering lower production emissions and compatibility with existing recycling systems. Studies, like those from Viscotec, show rPET’s economic benefits align with sustainability, making it ideal for businesses of all sizes, from small delis to global suppliers.
  • How can businesses switch to sustainable rPET packaging?
    Partnering with a trusted supplier like AVI Global Plast ensures a seamless transition. AVI produces 24,000 tonnes of rPET yearly, backed by 12+ international certifications for quality and sustainability. Contact them at info@avigloplast.com or +91 022-68559300 for tailored solutions to meet your packaging needs and compliance requirements.
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