PET thermoforms are commonly used for consumer goods, electronics and fresh produce packaging. They offer versatility, clarity and superior machine compatibility at a low cost. The problem arises when these packages reach the end of their life; PET thermoformed trays and clamshells do not easily fit into existing PET recycling streams, as they are contaminated with food, labels, inks and adhesives. This has led to lower collection and recycling rates, with most thermoforms ending up in landfills.
Emerging advancements in PET thermoform recycling
However, new efforts are emerging to close this loophole. Advanced sorting facilities can now separate PET thermoforms from single-stream collections. Technologies such as Near-Infrared (NIR), Density Separation, Optical Sorting, and X-ray scanners, and even AI-powered industrial robot sorting allow proper identification of PET thermoforms for recycling. The next step is reintroducing this recycled PET content into manufacturing supply chains.
Opportunities for companies to embrace circularity
Brands across industries are gradually recognising the need to incorporate recycled PET from thermoformed packaging into new packaging. Doing so minimises plastic waste while extending the circularity of PET material beyond PET bottles. Such tray-to-tray recycling was not possible in the past.
Overcoming challenges through collective action
The biggest challenge lies in securing a consistent supply of rPET (tray-to-tray) material at scale. This requires greater adoption of deposit return schemes, partnerships with waste management firms, and consumer awareness regarding the importance of better managing PET tray waste to keep this valuable input resource in the loop.
AVI Global Plast supplies rPET punnets to clients across industries, including fresh produce, which get collected after delivery, recycled by our partner recyclers, and supplied back to AVI as rPET flakes for new punnets—enabling a circular economy.
