greenPLAST-food

Despite their significant share in food packaging applications, polypropylene (PP) and polyethylene (PE) are currently rarely processed into high-quality recyclates suitable for food contact materials (FCM). Existing approved recycling processes focus almost exclusively on PET, whereas PP and PE are predominantly downcycled. This prevents the establishment of a true material loop and runs counter to the objectives of the EU circular economy. The absence of effective decontamination processes, insufficient material quality, and high energy requirements further hinder the recycling of these polyolefins. The greenPLAST-food project directly addresses these challenges by developing innovative technologies to enable safe and efficient recycling solutions for PP and PE in food contact materials, thereby closing existing gaps.

The greenPLAST-food project is structured into nine coordinated work packages (WPs), which together aim to develop a scalable and energy-efficient recycling process for polypropylene (PP) and polyethylene (PE) packaging waste. The objective is to produce high-quality recyclates that comply with the stringent regulatory requirements for food contact materials (FCM).

At the outset, WP2 and WP3 focus on optimising existing recycling processes for PP and PE waste, with particular emphasis on decontamination performance and material quality. WP4 develops an AI-based sorting system to enhance the purity of input materials, thereby establishing the basis for high-quality recyclates. WP5 addresses the energy efficiency of process steps, for example through heat recovery and the use of renewable energy sources. WP6 validates the food safety of the recyclates in accordance with regulatory standards.

The core of the project is WP7, which develops a blueprint for a sustainable recycling facility. This “green factory” follows the Safe and Sustainable by Design (SSbD) approach, taking into account environmental, social, and economic sustainability criteria. WP8 and WP9 ensure effective dissemination of results, impact assessment, and the engagement of relevant stakeholders.

The greenPLAST-food project aims to achieve several key outcomes to fundamentally improve the recycling of polypropylene (PP) and polyethylene (PE) for food contact materials (FCM). At its core is the development of high-quality, food-safe recyclates that comply with EU regulations (including Regulations 1935/2004, 10/2011, and 2022/1616). To this end, a comprehensive recycling process is designed, encompassing AI-based sorting, energy-optimised washing and decontamination steps, and subsequent conversion into FCM.

A central outcome is the development of a transferable blueprint for a green recycling facility, which will be piloted at the Enns site (Upper Austria) and subsequently scaled across Europe. The process design follows the “Safe and Sustainable by Design” (SSbD) principle, comprehensively addressing environmental, social, and safety aspects.

In addition, the project is expected to deliver tangible contributions to the reduction of greenhouse gas emissions, the advancement of the circular economy, and the strengthening of the innovation capacity and competitiveness of the European recycling system. Through targeted dissemination and knowledge transfer activities, the project will also enhance public awareness and acceptance of high-quality recycling solutions.