Klöckner Pentaplast’s Recyclable Trays Aim to Cut Food Waste

Klöckner Pentaplast expands recyclable packaging into fresh produce

Klöckner Pentaplast has introduced its kp Infinity fruit tray range for packed fresh fruit. The trays are made from expanded polypropylene, a fully recyclable mono-material that replaces traditional expanded polystyrene packaging. This marks an extension of the kp Infinity portfolio, which launched in November 2019 for the food-to-go sector.

The move responds to growing demand for recyclable produce packaging. Fresh fruit supply chains have historically relied on expanded polystyrene trays, which present recycling challenges. By contrast, these new trays can be processed through existing polypropylene recycling streams.

For UK businesses supplying fresh produce, the shift reflects broader changes in packaging requirements. Retailers increasingly specify recyclable materials as standard. Meanwhile, customer expectations around sustainability continue to influence purchasing decisions across the supply chain.

Material specification and environmental testing

The trays use expanded polypropylene throughout their construction. This single-material approach simplifies end-of-life processing compared to multi-layer alternatives. Consequently, the packaging can move through standard recycling infrastructure without additional separation steps.

Klöckner Pentaplast commissioned an independent Life Cycle Assessment to verify environmental performance. The assessment measured energy consumption, water use, and carbon emissions across the product lifecycle. Results showed the trays generate less CO2 equivalent than alternative packaging materials currently used for fresh fruit.

Specifically, the manufacturing process requires reduced energy and water inputs compared to conventional options. These savings accumulate across production volumes. For businesses managing environmental reporting, this data supports Scope 3 emissions calculations related to packaging procurement.

The trays also offer practical features for food handling. They are microwaveable, water resistant, and oil resistant. Additionally, they retain heat longer than some alternatives, which matters for certain supply chain applications.

Recyclability infrastructure and consumer messaging

Each tray carries printed recycling instructions aimed at consumer disposal. Clear labelling helps increase recycling rates by reducing contamination and improving sorting accuracy. However, effectiveness depends on local collection systems accepting polypropylene.

In the UK, most kerbside collections now handle polypropylene packaging. Nevertheless, businesses should verify regional variations before switching materials. Some areas have better infrastructure than others for processing expanded polypropylene specifically.

The trays feature what Klöckner Pentaplast describes as a traditional artisan appearance. This design choice addresses consumer perception alongside functional requirements. Research suggests packaging aesthetics influence purchase decisions for fresh produce, particularly in premium segments.

From a circular economy perspective, mono-material packaging aligns with extended producer responsibility requirements. The UK’s packaging regulations increasingly favour materials that can be readily recycled. Therefore, switching to fully recyclable options may reduce compliance costs over time.

Company context and sustainability commitments

Klöckner Pentaplast operates globally across pharmaceutical, medical, food, and beverage packaging markets. The company has established several public sustainability targets tied to material sourcing and emissions reduction.

In 2023, the business used 120,000 tons of post-consumer recycled content in its operations. This demonstrates existing infrastructure for handling recycled materials at scale. By 2025, the company aims to incorporate at least 30% post-consumer recycled material across its packaging portfolio.

Emissions data provides further context. In 2024, Klöckner Pentaplast reported total greenhouse gas emissions of approximately 1.7 billion kg CO2 equivalent across all scopes. Scope 3 emissions, which include supply chain impacts, accounted for the majority. By 2030, the company targets a 20% reduction in Scope 3 emissions per product sold.

These figures matter for UK businesses conducting supply chain emissions assessments. Packaging represents a significant component of Scope 3 calculations for food producers and retailers. Consequently, choosing suppliers with verified reduction targets can support your own net zero planning.

Application to UK supply chains and procurement

The fruit tray launch extends proven technology into a new market segment. Fresh produce packers, processors, and retailers represent the primary audience. For these businesses, packaging decisions involve balancing cost, product protection, shelf appeal, and environmental performance.

Traditional expanded polystyrene offers excellent cushioning and thermal properties. However, its recycling limitations create problems. Many consumers cannot recycle polystyrene through household collections. As a result, this material often ends up in residual waste streams.

Switching to expanded polypropylene addresses this issue while maintaining protective qualities. The material absorbs impacts during transport and storage. It also provides insulation, which matters for temperature-sensitive produce moving through multi-stage distribution networks.

Cost implications will vary by volume and specification. Expanded polypropylene typically commands a price premium over polystyrene. Nevertheless, total cost calculations should include disposal fees, which may favour recyclable options in some regions. Furthermore, avoiding non-recyclable packaging can reduce Extended Producer Responsibility fees under current and planned UK regulations.

For businesses tendering for retail contracts, packaging specifications increasingly appear in technical requirements. Major supermarkets have published commitments to eliminate hard-to-recycle materials. Therefore, adopting recyclable alternatives proactively may strengthen competitive positioning.

Compliance and reporting considerations

UK packaging regulations continue to evolve. The Extended Producer Responsibility scheme, which took effect in stages through 2024, places responsibility on packaging producers and importers. Higher fees apply to materials that cannot be easily recycled.

Polypropylene generally qualifies as recyclable under these definitions, subject to collection and reprocessing infrastructure. By contrast, expanded polystyrene faces restrictions in some contexts. Businesses should review the specific definitions applied by regulators when making material choices.

Carbon reporting represents another driver. Companies measuring Scope 3 emissions must account for purchased goods and services, including packaging. Choosing materials with lower embodied carbon reduces reported emissions. For businesses working toward Science Based Targets or net zero commitments, packaging decisions directly affect progress.

Public sector suppliers face additional considerations. Procurement Policy Note 06/21 requires carbon reduction plans for contracts above certain thresholds. These plans must address supply chain emissions. Consequently, demonstrating recyclable packaging adoption can strengthen tender responses.

The net zero program for carbon reporting compliance covers how businesses can structure Scope 3 assessments and identify material reduction opportunities across operations and supply chains.

Practical considerations for material transitions

Switching packaging materials requires technical validation. Produce varies in weight, moisture content, and handling requirements. Therefore, businesses should test expanded polypropylene trays with their specific product range before full rollout.

Distribution networks also need assessment. The trays must withstand stacking, vibration, and temperature fluctuations during transport. Failure rates during trial periods provide essential data. Similarly, retail display conditions affect performance, particularly for chilled or ambient products.

Consumer acceptance represents another factor. While environmental benefits matter, shoppers also evaluate appearance, perceived quality, and ease of use. Packaging changes sometimes trigger unexpected reactions. Consequently, gathering customer feedback during pilot programs helps avoid problems at scale.

Equipment compatibility matters for automated packing lines. Expanded polypropylene trays may behave differently than polystyrene in filling, sealing, or wrapping machinery. Engineers should verify dimensional tolerances and adjust settings accordingly. Downtime during changeovers can be minimised through advance planning.

What UK fresh produce businesses should consider

Five key points summarise the commercial implications for UK businesses:

• Expanded polypropylene fruit trays offer a fully recyclable alternative to traditional polystyrene packaging, aligning with Extended Producer Responsibility requirements and retail sustainability specifications.
• Independent Life Cycle Assessment confirms lower carbon emissions and reduced energy consumption compared to alternative materials, supporting Scope 3 emissions reporting and net zero targets.
• The mono-material construction simplifies recycling through existing UK infrastructure, potentially reducing disposal costs and improving end-of-life processing rates.
• Switching requires technical validation for specific produce types, distribution conditions, and packing equipment to ensure performance matches or exceeds current standards.
• Major retailers increasingly specify recyclable packaging in supplier agreements, making material transitions a competitive factor in tender processes and contract renewals.

Advisory view for produce suppliers and retailers

We regularly work with food businesses navigating packaging transitions. Several themes emerge consistently from these discussions.

First, material changes rarely happen in isolation. Packaging decisions connect to broader sustainability strategies, including carbon reporting, waste reduction, and supply chain resilience. Businesses benefit from treating packaging as part of an integrated approach rather than a standalone switch.

Second, cost comparisons need careful framing. Initial material prices tell only part of the story. Total cost includes disposal fees, potential Extended Producer Responsibility charges, labour for handling, and storage space requirements. In some cases, recyclable options prove cost-neutral or even advantageous when these factors are included.

Third, timing matters. Businesses already planning packaging reviews can incorporate recyclable options without additional disruption. Those locked into long-term contracts may face constraints. However, building recyclability requirements into next-round specifications positions you well for future regulatory changes.

Fourth, supplier relationships affect outcomes. Packaging providers vary in their technical support, testing capabilities, and willingness to customise solutions. Businesses should evaluate suppliers on service quality alongside material pricing. Strong partnerships smooth implementation.

Finally, communication supports adoption. Staff need clear guidance on handling new materials. Customers appreciate explanation of environmental benefits. Retailers respond positively to proactive engagement on sustainability initiatives. Therefore, internal and external messaging deserves attention alongside technical rollout.

Our sustainable procurement support helps businesses evaluate packaging options within broader supply chain sustainability frameworks, covering material selection, supplier assessment, and compliance alignment.

Additional information sources

Businesses considering recyclable packaging transitions can access further detail through several authoritative sources.

The Department for Environment, Food and Rural Affairs publishes guidance on Extended Producer Responsibility for packaging, including definitions of recyclable materials and fee structures. This information helps businesses understand compliance requirements and cost implications.

The Waste and Resources Action Programme provides technical resources on packaging recyclability, collection infrastructure, and design guidelines. Their reports cover UK-specific recycling systems and material processing capabilities.

For carbon measurement, the UK Government’s greenhouse gas reporting conversion factors offer standardised emissions data for packaging materials. These figures support Scope 3 calculations and enable consistent reporting across organisations.

Trade bodies such as the Food and Drink Federation publish sector-specific guidance on packaging sustainability. Their resources address practical implementation challenges and share case studies from member companies.

Finally, our ESG compliance and carbon reporting services support businesses working through Scope 3 assessments, net zero planning, and sustainability reporting requirements across operations and supply chains.