New Technologies to Reduce Virgin Plastic in Rigid Packaging

Snacking Made Right

This challenge seeks proven, scalable technologies for virgin plastic reduction (VPR) in rigid plastic containers currently manufactured from HDPE or PP, with a focus on food safety, performance, and sustainability.

Application Deadline
January 25th, 2025
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Summary

Background

Virgin plastic, commonly used in rigid plastic containers, refers to material that has not been processed or recycled beyond its initial production from natural gas, crude oil, or biological resources. High-density polyethylene (HDPE) and polypropylene (PP) have long been essential in packaging due to their durability and ability to protect products. However, with increasing focus on sustainability, there is a growing push to minimize the environmental impact of packaging materials. Advances in recycling technologies and packaging innovations now offer opportunities to significantly reduce virgin plastic usage by adopting eco-friendly solutions that promote the reduction, reuse, and recycling of plastics.

Despite these advances, reducing virgin plastic content in rigid containers poses challenges, such as maintaining the structural integrity and barrier properties necessary for product protection. Additionally, these solutions must meet stringent food safety regulations, particularly in regions like the Gulf, Thailand, China, and India. Overcoming these hurdles requires a balanced approach that integrates innovation, cost-effectiveness, and environmental responsibility.

Challenge

There are 3 main areas that Mondelez are excited to explore:

1. Packaging innovation leveraging new technologies: Continuously evaluate and trial new technologies (material, processing, and design) with the potential to improve the sustainability of packaging, supporting the concept of circularity.

Understanding innovation in current Extrusion blow moulding, Injection moulding process and any new technologies.

2. Aim to replace plastic with paper where environmentally favourable: Replace plastic with recycled or sustainably sourced renewable materials such as paper, where environmentally favourable, to support the concept of circularity. Repulp ability test requirement.

3. Replace virgin plastic with recycled plastic via mechanical and chemical recycling: Maximise use of post-consumer recycled content in packaging, especially in plastics, to support the concept of circularity. Mechanical recycling for non-food contact only:


  • India – Bournvita
  • Thailand – Stride Gum bottles, Stride Vial 
  • Gulf Countries – Tang 2Kg tub
  • Australia - Philadelphia


Key watch outs:

  • Performance: Solutions must retain mechanical strength, including stiffness, toughness, and moisture/oxygen barrier properties, particularly for hygroscopic products.
  • Regulatory Compliance: All materials must meet food safety standards, especially in the Gulf and India, where restrictions on certain recycled plastics exist.
  • Sustainability: Emphasis should be placed on sustainable packaging materials like PP, PE, avoiding other plastics such as PVC, polycarbonate, and carbon black pigments.

Cost competitive- Proposed solutions must be cost-competitive with existing materials (PP/HDPE) and processes (extrusion stretch blow moulding).


What's in it for you?

Successful solutions will provide multiple advantages for both individuals and organisations:

1. Sustainability Leadership: Your innovative solution could position you or your organization as a solution provider in the sustainable packaging space to Mondelez. Collaborating on this challenge could lead to co-developing the solution with major global brands, unlocking potential and commercializing opportunities.

2. Global Impact and Recognition: Reducing virgin plastic use in rigid containers aligns with MDLZ global sustainability goals, and would offer a chance to make a tangible environmental impact while gaining recognition for your contribution to advancing packaging innovation across MDLZ global platform.

This challenge is open to individuals, research institutions, and organizations, with solutions at any stage of development. We encourage you to submit your expertise and become a part of this critical initiative for reducing virgin plastic and promoting sustainable packaging solutions.