Coexpan and Eslava announce food-grade recycled polystyrene

A major obstacle to plastic packaging circularity — making post-consumer polystyrene (PS) safe for food contact — has been overcome with Coexpan and Eslava jointly pioneering mechanical recycling technology to produce food-grade recycled PS (rPS).

The collaborative project, now in advanced validation stages, provides a crucial solution for the dairy sector and other food producers who rely heavily on PS, such as for yoghurt cups.

This advancement enables true material circularity, meaning “a yoghurt cup can be turned back into another yoghurt cup, thus closing the product’s life cycle,” the companies stated.

Given that over 350,000 tonnes of polystyrene were used in yoghurt packaging alone in 2024, the ability to reintroduce this post-consumer volume back into the food circuit represents a massive step toward a more sustainable and resilient packaging model.

The solution is centred on mechanical recycling, which the European Union favours as the most sustainable route due to its lower carbon footprint. Eslava contributes essential expertise in separation and purification, utilising artificial intelligence to ensure a stable supply of high-quality recycled feedstock.

“This project reflects Grupo Lantero’s commitment to responsible innovation and the creation of solutions that bring real value to our customers,” said Daniel Carreño, CEO of Grupo Lantero. “We are not only responding to regulatory requirements, but also leading a necessary transformation for the future of food packaging in Europe.”

The initiative is specifically designed to meet the rigorous demands of the new PPWR Regulation, which will mandate the inclusion of recycled content in PS packaging intended for food contact.

The core of the technology lies in its advanced decontamination system, which transforms post-consumer waste — material that has already been used by the consumer — into recycled raw material that complies with the highest food safety standards.

David Eslava, CEO of Eslava, highlighted the significance of the achievement. “After many years of work and development… we are proud to contribute to a solution that shows mechanical recycling can be safe, efficient, and truly circular, and that positions Spain as a leader in sustainable innovation.”

Sergio de Freitas, CEO of Coexpan, emphasised the strategic nature of the partnership. “This project is a clear example of how strategic collaboration and technological innovation can produce real and scalable solutions to the sector’s sustainability challenges,” he commented. “At Coexpan we are proud to lead this development, which not only closes the polystyrene loop but does so with guarantees of food safety and industrial efficiency.”