Our team receives lots of questions and inquiries about our mechanically recycled LLDPE PCR for food grade flexible packaging applications. We decided to sit down with Tammy Rucker, the Vice President of Sustainable Materials, to learn more about the product. Here is what she shared with us:
Revolution offers an LNO PCR resin. What exactly is LNO PCR?
LNO PCR carries a “Letter of No Objection” from the FDA. This means the FDA has evaluated the quality and purity of the material and does not object to it being used in food-contact packaging – in other words, it’s safe to come into direct contact with food items. There is a lot more that goes into producing a food-grade PCR, but an LNO is the first step.
What is required to obtain an LNO from the FDA?
Most importantly it’s about the source of the plastic waste and the process used to create food-grade PCR resin. The FDA requires that you outline and document your recycling process and then prove the ability of this process to remove any contaminations that might make it non-food safe.
How is Revolution’s LNO different from others available in the market today?
Revolution’s PCR is more consistent than most other LNO resins. We control the plastic waste from end to end before it enters our recycle process. This means we don’t have to deal with the variation that comes from mixtures of different types of plastics.
What applications would be appropriate for Revolution’s LNO PCR?
We have very broad conditions of use* relative to other LNO PCRs on the market today – B through H. So, our LNO PCR can be used in flexible packaging designed to be reheated – like frozen dinners or microwaveable frozen vegetables. This is nearly the same as virgin LLDPE, except virgin can be used in high temperature heat-sterilized applications. Our LNO PCR is clean, fractional melt LLDPE derived from a Hexene-rich film source which makes it ideal for blown film processing. The LNO PCR is also white in color, so think about frozen vegetable bags, stand-up packages, or a sealant film in a multilayer system.
*You can read the full list of Conditions of Use on the FDA’s website.
What is the key to Revolution’s quality?
Revolution focuses on exceptional manufacturing practices and product chain of custody. Preventing cross-contamination of plastic films during collection and production is key to achieving low gels. We developed and optimized our wash and recycle process specifically for blown film.
How has the market responded to your LNO PCR so far?
The market is hungry for a mechanically recycled food contact solution. There are many opportunities we are supporting currently. What we have learned so far is that the approval process for LNO PCR application can take time.
Which customer segments or industries have shown the most interest in LNO PCR?
Flexible food packaging is the best fit for our LLDPE LNO PCR resin. Within flexible food packaging, we have seen the most success in sealant film applications. The PCR resin is very clean and consistent, which lends itself to perform well as a sealant layer. Our LNO PCR is white in color, which is an added benefit to this application, which is commonly white anyway.
What are some of the biggest challenges/barriers to entry for incorporating LNO PCR the industry faces, and how is Revolution addressing them?
I think the biggest challenge is the extensive regulatory requirements for direct food contact packaging. We have made a significant investment in testing, and this has removed many potential barriers and greatly reduced the risk and costs of approving LNO PCR use for customers.
How do you see the regulatory landscape evolving for LNO PCR in the next few years, and what steps is Revolution taking to stay ahead of these changes?
The industry has taken on some big regulatory issues recently. The most urgent has been PFAS. Now that its health impact is better understood, states are rushing to restrict or ban certain types of PFAS chemicals. The packaging industry is dealing with the challenge of addressing the problem as we gain more understanding of how to measure PFAS, what specific PFAS chemicals are most problematic, and what amounts are harmful. I have personally seen a high level of seriousness from our customers in tackling PFAS. They have required information and understanding of the potential of PFAS in our recycled resins. We are fortunate to have control over our LNO PCR feedstock and know that the original film product does not use or contain polymer processing aides (which can be based on PFAS). We have been proactive in testing for PFAS and have backed up our findings with statements of assurance.
How is Revolution preparing to meet the anticipated market needs and challenges for LNO PCR in the coming years?
We are always working to expand our products and capacity, and we are constantly looking for circular and direct collection feedstock opportunities. Chain of custody is essential to providing food contact assurances.
Are there any notable applications you can share that highlight the successful use of LNO PCR?
A notable application is Fresh-Lock’s enclosures for flexible packaging designed and produced by Presto Products, a business unit of Reynolds Consumer Products. They are using our food grade LLDPE PCR to achieve 25% mechanically recycled content. The Fresh-Lock team has been fantastic to work with. They have been eager to learn in depth about PCR so they can better address questions from their clients. The development team was interactive and led us to improve performance through process optimization.
What do you think are the next application successes for Revolution’s LNO PCR?
We are actively collaborating with film producers and converters to create sustainable packaging. A pouch made with a Fresh-Lock re-closable feature made with PCR is particularly appealing. Pouches are a food packaging area rich with opportunities such as for pet treats, nuts and snacks. These segments have consumers who are conscious of sustainability and would value recyclability and recycle content.
What is next on the horizon for Revolution in the PCR and recycle space?
We are not sitting still, that is for sure. Future capacity expansions are in progress and coming soon. We’ve recently invested in technology to (nearly) continuously monitor our food contact PCR resin production, ensuring we meet the highest standards of food safety. Additionally, we are exploring blending our PCR with virgin resin to optimize melt flow for specific applications and have already blended PCR grades to enhance film properties. With our film sources and assets, we have the tools to provide tailored solutions. We’re ready to help you maximize recycled content—just reach out and give us a call. We’re here to help!
Ready to learn more about Revolution’s LNO PCR and how it can help your business achieve more sustainable packaging solutions? We’re available to talk any time, so reach out and let’s connect.