PET thermoform recycling the focus of new NAPCOR white paper

That National Association for PET Container Resources (NAPCOR) has released a new white paper, “Increasing PET Thermoform Recycling,” aimed at California policymakers working to design and implement the Plastic Pollution Prevention and Packaging Producer Responsibility Act, or Senate Bill 54, as well as any others developing extended producer responsibility (EPR) legislation.

According to Middleton, Wisconsin-based NAPCOR, the white paper discusses the many attributes and applications of PET (polyethylene terephthalate) thermoforms, the evolution of the industry, strategies to enhance PET thermoform recycling and provides policy recommendations supporting PET thermoform circularity.

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The white paper was created in partnership with the Circular PET Thermo-Forum, a coalition of 25 thermoform manufacturers and recyclers across North America and is free to download.

NAPCOR notes that PET is a clear, durable, lightweight, versatile and food-safe plastic and is considered the most recycled plastic in the world. Thermoformed PET, in particular, is created by heating a PET plastic sheet until it becomes pliable, then shaping and trimming it into the desired form, and is used for packaging produce, baked goods, dairy items, meat, eggs, ready-to-eat meals, electronics, toys and more. NAPCOR says PET thermoforms’ recyclability makes them a preferred choice for companies looking for sustainable packaging.

NAPCOR says its white paper comes at a critical time for California as Gov. Gavin Newsom recently instructed the state’s Department of Resources Recycling and Recovery (CalRecycle), to start over on S.B. 54 negotiations.

“Our members have a strong desire to see thermoform recycling succeed, but proper infrastructure, guidelines and investments are needed to advance further PET thermoform circularity in California and elsewhere,” NAPCOR Executive Director Laura Stewart says. “We believe that the right collective action between policymakers, brand owners, producers and recyclers will ultimately create a future where PET thermoforms contribute meaningfully to a sustainable supply chain and a circular economy—thereby reducing plastic pollution.”

NAPCOR says the PET recycling industry has undergone substantial innovation and growth, demonstrating a “significant evolution” in its ability to handle diverse material streams without compromising the integrity of existing PET bottle recycling processes. According to the organization’s 2023 PET Recycling Report, published in December 2024, PET thermoform collection increased more than three-fold over the previous 12 years—outpacing the growth in bottle collection. The white paper details, however, that there still is significant potential to increase recycling rates for PET thermoforms as a commingled stream with PET bottles or further separated into thermoform-only bales.

The white paper discusses why achieving the circularity for PET thermoforms at an impactful scale is not just a possibility but an imperative for the future of sustainable packaging. NAPCOR says recycling advancement methods and collaborative efforts detailed in the white paper show the broad innovation already applied within the industry.

Enhancing recycling

The white paper outlines several ways to enhance PET thermoform recycling, claiming that the process starts with "robust education and community engagement."

The paper notes that many consumers are unaware PET thermoforms such as clamshells and trays are recyclable, and many do not know if their local recycling programs accept such items. "This lack of awareness leads to significant material loss," the paper says, adding that research conducted by The Recycling Partnership (TRP) shows the U.S. curbside recycling system only recovers about 32 percent of available materials from single-family homes.

Compared to the U.S. PET bottle recycling rate of 33 percent, the white paper says PET thermoforms are recycled at a rate of about 14 percent. In California, TRP data indicates this difference has more to do with gaps in recycling engagement than inadequate access to recycling programs. Although TRP estimates that 78 percent of communities have access to recycling programs that accept PET thermoforms, only 23 percent are collected by California residents.

"Municipalities can collaborate with organizations to develop comprehensive educational initiatives that bridge these knowledge and participation gaps, such as creating and distributing educational materials, conducting recycling workshops and implementing clear curbside recycling guidelines," the paper states.

Additionally, the paper calls for continued recycling infrastructure development, such as investment in advanced recycling technologies and improved sorting at material recovery facilities (MRFs).

Making the law work

The report concludes with three recommended policy approaches NAPCOR and the Circular PET Thermo-Forum say they hope to see in the next iteration of S.B. 54—favorable fee eco-modulation, equitable responsible end market identification and nonmechanical recycling pathways.

Eco-modulation refers to adjusting fees within EPR frameworks to encourage more sustainable packaging choices. The white paper says these fees incentivize producers to make decisions that reduce negative environmental impacts in their packaging constructions and suggests thermoformed packaging incorporating postconsumer recycled (PCR) content, sourced from thermoforms and returned to the same market, deserves additional incentives.

When it comes to responsible end markets, NAPCOR and the Circular PET Thermo-Forum recommend the redefining of criteria for plastics to include entities that either process the material into a new form ready for manufacturing, such as flake or pellets, or directly incorporate the recycled material into a new product. 

"This revision would streamline the identification process, align with market realities for recycled PET, and ensure equitable treatment of plastics, metal and paper," the organizations write.

“There is no question that California and the nation can overcome hurdles to widespread PET thermoform recycling through additional targeted innovation, strategic policy alignment and industry commitment,” says Dan Kuehn, chair of the Circular PET Thermo-Forum and president and CEO of Cross Plains, Wisconsin-based thermoformer Plastic Ingenuity. “As the PET industry continues to evolve, embracing these solutions will enable a robust, circular economy where PET thermoforms are recycled and continuously reintegrated into the value chain.”