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Klöckner Pentaplast (Kp) has partnered with Tesco and Hilton Foods to launch a UK-first initiative piloting the use of 100% recycled PET (rPET) food trays made from recovered tray material.

The trial is part of Kp's Tray2Tray initiative. As part of the pilot, Tesco’s Finest minced beef will be packaged in the 100% rPET Kp Tray2Tray and sealed with Kp FlexiLid, a high-performance barrier film containing 30% recycled PCR content.

Rebecca Harris, global account director at Kp, said: "While this is a pilot, it’s clearly a massive step forward for the packaging circular economy. We launched our Kp Tray2Tray initiative because valuable food-safe tray material enters the recycling loop, but all too often the rPET material is downcycled to other product applications. Until something changes and demand is boosted, the required collection, sorting and recycling at scale will not be sufficient. So, what we’re doing here has real significance."

She continued: “The pilot is a dream match. At Kp, we’re innovative designers of food packaging solutions driven by our ambitious Investing in Better sustainability strategy; Hilton Foods, focused on its Sustainable Protein Plan, creates and produces high quality packaged food, and Tesco has built sustainability into its purpose, strategy and business plans."

"Kp made a splash when we launched our first trays with 100% Kp Tray2Tray rPET from trays in the UK, and this real-world trial is the perfect opportunity to show what our experienced technical team has accomplished.”

Currently, only 5% of the estimated one million tonnes of PET trays produced annually in the EU are recycled back into food-grade trays. Kp’s Tray2Tray initiative seeks to increase this percentage by creating a dedicated supply stream of recycled PET from trays, ensuring materials are efficiently reused.

Andrea Jex, procurement director at Hilton Foods, added: “This achievement exemplifies the power of collaboration with our customers and suppliers to deliver market-leading innovation to the shelves. Through these strong, long-standing partnerships, we remain dedicated to creating cutting-edge solutions that align with the goals of our Sustainable Protein Plan and our customers ambitions, whilst upholding the highest standards of quality and product shelf life for their consumers.”

James Bull, head of packaging and food waste at Tesco, added: "We are determined to close the loop on our packaging – for it to be fully recyclable and contain recycled content wherever possible. We remain committed to reducing our environmental impact, and helping our customers to do the same, as we work together to protect our planet."

Harris concluded: "It’s not just about being first, it’s about setting a precedent. What we want to show in this proof-of-concept pilot is how our Kp Tray2Tray made from 100% rPET tray flake is a perfect 'drop-in' solution for retailers and packers. Switching incumbent packaging to more sustainable alternatives should be simple, so we’re showcasing the ease of transition without compromise. And, by doing that, we’re offering a glimpse into the future of food tray packaging circularity."