Packaging Innovations & Empack 2026 showcased live demonstrations of scalable, sustainable packaging solutions, including Prevented Ocean Plastic™'s food-safe recycled polypropylene (rPP) and Castle Colour's plastic-free FibreGuard barrier board.
At the NEC Birmingham on February 11-12, Prevented Ocean Plastic™ introduced the first mechanically recycled polypropylene meeting EU food-contact standards. The material is sourced from controlled collection of polypropylene cups in coastal communities and processed using Starlinger Viscotec technology. Innovia Films and Spectra Packaging are early adopters. The initiative aims to prevent 500 million cups from entering the ocean in its first year1Packaging Innovations & Empack 2026: ten packaging innovations taking centre stage - Food and Drink Technology.
Castle Colour presented its FibreGuard solution-a fibre-based, plastic-free board intended to replace laminate barriers. The board is targeted at food and cosmetics applications, aiming for improved recyclability and cost reduction. Castle Colour reported that FibreGuard has moved from testing to successful customer trials2Masses flock to Packaging Innovations & Empack 2026 as industry showcases sustainable breakthroughs - Food and Beverage Business.
Background
The packaging sector faces increasing regulatory and market pressure to cut plastic waste and enhance circularity. Polypropylene, while widely used, remains difficult to recycle; globally, less than 1% is recycled. Advancements in converting PP into food-safe recycled material address contamination and recyclability concerns3World-first food-safe recycled polypropylene for European markets – Innovations Food.
Concurrently, fibre-based packaging innovations are gaining ground as brands seek alternatives to plastic lamination. Certified plastic-free barrier materials, including plant-based coatings on cartonboard, are growing in importance under regulations like the EU Packaging and Packaging Waste Regulation1Packaging Innovations & Empack 2026: ten packaging innovations taking centre stage - Food and Drink Technology.
Details
Prevented Ocean Plastic™ uses a franchise model to collect PP waste before it reaches marine environments. The material is cleaned, processed, and validated in independent tests for EU food contact compliance. Innovia Films will use the recycled material for BOPP films, while Spectra Packaging plans applications in blow-molded bottles and caps3World-first food-safe recycled polypropylene for European markets – Innovations Food.
Paul East, Recoup's Head of Packaging Recycling & Design, stated at the event that Recoup undertakes real-world recycling trials by feeding packaging samples through materials recycling facilities to evaluate outcomes. Nestlé's Alison Bramfitt highlighted the importance of aligning material innovation with recycling infrastructure and supplier engagement to ensure effective scaling2Masses flock to Packaging Innovations & Empack 2026 as industry showcases sustainable breakthroughs - Food and Beverage Business.
Castle Colour's FibreGuard board provides a grease-resistant barrier without plastic lamination and supports cost savings under Extended Producer Responsibility (EPR) schemes. The company reported successful customer trials in food and cosmetics packaging sectors2Masses flock to Packaging Innovations & Empack 2026 as industry showcases sustainable breakthroughs - Food and Beverage Business.
Outlook
Prevented Ocean Plastic™ plans to expand rPP supply to support thousands of food-safe packaging applications over the next year. Castle Colour aims to bring FibreGuard to wider commercial use as demand for plastic-free, recyclable solutions grows under advancing EPR requirements.
