Overview:

Our client is seeking alternative materials for their microwave-safe frozen-food pouches (currently PET/PE or OPP films) that allow the packaging to be recycled at home in the UK (kerbside recycling compliant), eliminating the need for store drop-off recycling currently used for many plastic films.

 

Background:

Packaging and Packaging Waste Regulation (PPWR) and Extended Producer Responsibility (EPR) legislation limit plastic usage within the EU and UK, respectively.

The new PPWR will come into effect on 12 Aug 2026 and will require that all packaging placed on the EU market must be recyclable by design and be PFAS-free. Furthermore, by 1 Jan 2030, packaging must be ‘recyclable in an economically viable way’ and contain recycled content

The EPR scheme went into effect in January 2025 and currently taxes companies using films and flexible plastics due to their limited ability to be recycled kerbside.

 

Material Requirements:

Must:

• Kerbside recycling complaint – can be recycled at home within the UK
• Food safe – can be in contact with food without influencing its taste or smell
• Microwave safe – need to withstand the required temperatures without compromising food safety, structural integrity or quality of the product
• Freezer safe – withstand temperatures as low as -18°C.
• High material flexibility – should be “bag” like
• Mono-material (ideally 95% one material, but 90% may also be considered)

 

Should:

• Transparent
• Premium look and feel
• Integrate with client’s existing manufacturing infrastructure

Must-not:

• Multi-laminated material
• Biodegradable
• Materials which would cause packaging to fall below 90% recyclable

 

Possible Solution Areas:

Novel materials from either companies or research institutes, granted there is reproducible evidence that supports the above material requirements.

Desired outcome of the solution:

Connection with a material and/or packaging supplier that can provide microwave-safe and flexible material that can be used in the frozen food industry and can be recycled at home within the UK.

 

Related Tech Needs: 

Seeking: Recyclable Flexible Material Suitable for Packaging

Seeking: Novel Recyclable “Cook in Pack” Tray Material

 

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