From Waste To Food Use: How Plastic Granulation Reshaps The Future Of Food Packaging
1. Core Conclusion: The surge in food packaging has forced recycling and granulation technology to "break through upwards"
The global demand for food packaging is experiencing an unprecedented explosive growth. However, according to data from the United Nations Environment Programme, nearly 40% of global plastic production is used for packaging, with the vast majority being disposable, which puts enormous pressure on the environment. Faced with the upcoming implementation of the 2026 Global Plastic Treaty and the EU Packaging and Packaging Waste Regulations, the packaging industry is standing at a crossroads of change.
For international customers who pursue environmental protection and high cost-effectiveness, simply "recycling" is no longer sufficient to meet their needs. The real breakthrough lies in the upgrading of plastic recycling granulation technology - using high-precision equipment such as co rotating twin screw extruders to convert post consumer waste into food grade recycled particles that can rival new materials. This is not only a passive choice to respond to policies and regulations, but also an active strategy to seize the next generation of green packaging market.
2. Current situation and trends: 2026, the "compliance test" of food packaging and the "golden age" of recycled plastics
2.1 Policy coercion: from "voluntary environmental protection" to "mandatory legislation"
2026 is a key milestone for global plastic pollution control. The highly anticipated United Nations Global Plastic Treaty is expected to reach a final agreement this year, requiring member states to control the entire lifecycle of plastics. At the same time, the European Union has made it clear through legislation that the proportion of recycled plastic in PET bottles must reach 25% by 2025 and increase to 30% by 2030. The United States has also proposed that plastic bottles should contain 25% recycled content after consumption by 2025.
Key Q&A:
Q: What risks will my food packaging face if I don't use recycled materials?
A: If it does not comply, your product may be banned from entering major markets such as the European Union. International food giants such as Mars and Est é e Lauder have taken the lead in adopting 100% rPET packaging, creating a "green barrier" in the global supply chain.
2.2 Technical bottleneck: Why can't "low value garbage" become "high-value packaging"?
In the past, due to technological limitations, recycled plastics were often downgraded for use (such as being made into trash cans) and could not be used as food contact materials. The main reason is that:
·Pollutant residues: Traditional processes are difficult to remove ink, adhesive, and content residues, resulting in excessive levels of unintentional additives (NIAS) and posing a food safety hazard.
·Performance degradation: Multiple thermal processing leads to polymer chain breakage and a decrease in material mechanical properties.
3. Technological breakthrough: How to achieve "same level circulation" for co rotating twin screw extruders
To produce food grade recycled particles that meet the requirements of GB 4806.7-2023 "National Food Safety Standard for Plastic Materials and Products in Contact with Food", advanced mechanical recycling technology and core equipment must be relied upon.
3.1 Core equipment: "Superpower" of co rotating twin screw extruder
The co rotating twin screw extruder is the core engine of modern plastic recycling granulation production lines. Its advantage lies not only in mixing, but also in "refinement":
·Efficient devolatilization (degassing): Targeting the odor and volatile organic compounds (VOCs) that food packaging is most concerned about, high-end twin screw extruders such as KLWE series can efficiently remove residual pollutants such as toluene and limonene through a multi-stage vacuum devolatilization system, ensuring that the regenerated particles are pure and odorless.
·Mild thermal process: The same direction meshing design has excellent self-cleaning function, preventing materials from staying in the barrel for a long time and causing yellowing and black spots, which is crucial for producing light colored and highly transparent food packaging.
Key Q&A:
Q: What are the advantages of co rotating twin screw extruders in processing multi-layer composite films (such as potato chip bags)?
A: Multi layer composite films are difficult to disperse with traditional single screw due to mixed materials. In the plastic extrusion process, the powerful shear and distribution mixing ability of the twin screw can fully homogenize different polymers. Combined with a special side feeding system, it can directly process fluffy scraps and achieve closed-loop recycling. In practical applications, this technology can increase the recycling yield of multi-layer films from about 160 kg/h to 1400 kg/h.
3.2 Process Innovation: Upgrading and Rebuilding from Physical Recycling
In addition to melt granulation, the latest recycling plastic granulation technology is moving towards "upgrading and recycling":
·PET bottle to bottle recycling: This is the benchmark for food grade recycling. By integrating a co rotating twin screw extruder system, production can be carried out without pre drying, reducing energy consumption by up to 30%. At present, the single machine production capacity has expanded from 1-2 tons per hour to over 9 tons. The rPET particles produced have been approved by the US FDA and European EFSA and can be directly used for the production of new beverage bottles.
·Hard polyolefin recycling: For PP/PE daily miscellaneous materials, an integrated solution of "melting high-precision filtration multi-stage devolatilization post solid phase deodorization" can effectively remove long-chain odor molecules that migrate into the polymer matrix. The final particles are close to their original quality and can be applied to food packaging films or injection caps.
4. Data and Standards: Security compliance is the "passport" to enter the international market
4.1 Safety standards are becoming increasingly stringent
On September 16, 2025, China officially implemented five new national standards for the determination of food contact materials in the GB 31604 series, which set clear migration limits for unintentional additives in recycled plastics (such as 2,2,4,4-tetramethyl-1,3-cyclobutanediol, nitrosamines, etc.).
·Data support: Studies have shown that the concentration of limonene, a common pollutant, is significantly higher in PP and HDPE recycled materials than in PET, and must be removed through efficient devolatilization processes.
·International integration: EU Regulation (EU) 2022/1616 explicitly requires that recycled plastics used for food contact must demonstrate their decontamination efficiency. At present, recycling production lines that have obtained EFSA or FDA certification have produced rPET particles that have been recognized by top beverage brands worldwide.
4.2 Carbon Footprint Advantage
Replacing virgin plastics with recycled plastic pellets has significant carbon reduction benefits. The introduction of the new EU regulation GB/T 45441-2025 "Methods and Requirements for Quantifying the Carbon Footprint of Greenhouse Gas Products - Plastic Products" means that in the future, carbon footprint values may be marked on packaging, and the carbon footprint of recycled plastics is usually much lower than that of virgin plastics.
5. Economic benefits and future prospects: a cost-effective "new material substitution" solution
For international clients who are new to us, we understand your concerns about recycled plastics - is it stable? Is it cost-effective?
5.1 Balance between Cost and Performance
The advancement of plastic extrusion granulation technology has enabled recycled materials to approach new materials infinitely in key indicators such as melt index (MFR) and tensile strength. By adjusting the formula (such as adding toughening agents, fiberglass), it is even possible to "customize" modifications for specific packaging needs. Research has shown that through advanced sensor sorting combined with co rotating twin screw extruder processing, the melt index of white PP recycled material can even reach nearly twice that of the raw material, and the rigidity is stronger (Young's modulus 1424 MPa vs 1154 MPa), providing the possibility for high-value applications.
5.2 Avoiding the risk of "greenwashing"
Under the upcoming strict supervision, slogans alone cannot establish a foothold. Reliable physical recycling (mechanical recycling) achieved through high-quality granulation using co rotating twin screw extruders is currently the most mature and lowest carbon footprint circular economy path.
Key Q&A:
Q: We want to try making new materials, but are concerned about the large fluctuations in the quality of recycled materials, which may affect the brand image?
A: This is a lingering impression of early recycling technology. The modern recycling plastic granulation production line, especially the system with co rotating twin screw extruder as the core, is equipped with precise metering feeding, high-precision melt filtration, and closed-loop control system. The produced particles have extremely high batch consistency in color, viscosity, and cleanliness. By using GB/T 45090-2024 "Identification and Labelling of Recycled Plastics" for clear labeling, you can also demonstrate your environmental responsibility to consumers and increase brand premium.
Conclusion
As the demand for food packaging continues to grow, plastic should not become a burden on the environment, but rather a resource that can be infinitely recycled. Through advanced recycling plastic granulation technology driven by co rotating twin screw extruders, we can not only process mountains of waste plastics, but also produce safe, clean, and high-performance food grade recycled particles.
This is not only a safe haven to cope with the global policy storm of 2026, but also a necessary path to achieve a win-win situation for sustainable development and commercial value.
