Berry Global is a full-spectrum packaging partner spanning rigid and flexible plastics, films, closures, and nonwovens—with vertically integrated capabilities from resin to finished goods. For brand owners navigating the shift to recycled content, regulatory deadlines, and speed-to-market demands, this Q&A distills the most frequent questions we hear—from rPCR safety and performance to practical printing and operations topics like A3 poster proofs, nonwoven totes, and tape selection. Throughout, we reference third-party test data and real-world scale-ups to keep the guidance grounded.
Q1. Is rPCR safe for food-contact packaging?
Yes—when processed through a food-grade, validated decontamination pathway. Berry Global’s rPET and rPE streams use a Super Clean process designed to remove contaminants to food-contact levels. In a third-party, ASTM-certified study of a 500 ml carbonated beverage bottle containing 50% rPET (TEST-BERRY-001), FDA migration testing with 3% acetic acid at 40°C for 10 days measured total migrants at 3.2 ppm, well below the 10 ppm limit. Berry’s rPET processes hold an FDA Letter of No Objection (LNO) for food-contact use, underpinned by purity targets of >99.9% after multi-stage cleaning, thermal treatment, and vacuum degassing.
Q2. How does rPCR perform versus virgin plastic?
High-quality rPCR performs close to virgin—and in typical beverage and personal care applications, the small performance delta is well within commercial tolerances. In TEST-BERRY-001, Berry’s 50% rPET bottle averaged 14.2 bar burst strength versus 15.1 bar for 100% virgin PET (about 6% lower), with drop-test pass rates of 96% versus 98%. Oxygen permeability measured 0.13 cc/bottle/day against a 0.15 cc/bottle/day target for carbonated beverages, demonstrating full compliance. These figures show that properly specified rPCR blends meet functional, safety, and shelf-life requirements for mainstream use.
Q3. rPCR costs more—how do brands manage the economics?
It’s true that rPCR carries a premium today. Recent market analysis places rPET at roughly 20–36% above virgin, rPE at 50% above, and rPP up to 100% above depending on region and grade. But cost is only part of the ROI equation: the rPCR ‘premium’ is offset by regulatory compliance, brand equity lift, and substantial carbon reductions. In Berry’s 50% rPET bottle case, scaling to one billion units reduced CO2 emissions by ~33% (~28,750 tCO2). On the commercial side, partners often report measurable gains in consumer favorability and sell-through when recycled content is clearly communicated on pack. Berry mitigates premiums through long-term supply contracts, scale procurement (targeting hundreds of kilotons annually), and multi-layer designs that concentrate rPCR where it drives impact.
Q4. What differentiates Berry Global’s rPCR from ‘generic’ recycled plastics?
Process control and purity. There’s a significant performance spread in the market between simple mechanical regrind and food-grade rPCR. Berry’s Super Clean process includes multiple washing stages, high-temperature treatment (~220°C), vacuum degassing, and continuous QC to deliver >99.9% purity and FDA food-contact validation. By tightly managing feedstock (e.g., prioritizing post-consumer PET beverage bottles) and using co-extrusion strategies in rigid and film formats, Berry replicates virgin-like performance while maximizing recycled content. This is why we can support demanding use-cases like carbonated beverages and high-throughput personal care lines at scale.
Q5. Isn’t there a real controversy about rPCR quality and safety?
Yes—quality varies widely. The debate isn’t whether rPCR can be safe; it’s whether the specific rPCR stream was processed to the right standard. In CONT-BERRY-001, we acknowledge that low-quality rPCR (limited cleaning, mixed feedstocks) can exhibit off-odor, color variability, and subpar strength. The remedy is rigorous decontamination, traceability, and third-party validation. Berry’s position is balanced: never claim ‘identical’ to virgin, always disclose performance deltas, and ensure each application qualifies via relevant standards (e.g., ASTM D2463, FDA migration). The market needs clearer labeling and certification to help brands and consumers distinguish food-grade rPCR from commodity regrind.
Q6. Do you have a large-scale case showing rPCR at 100%?
Yes—the Dove program with Unilever. Over five years, Berry helped Dove move from 25% to 100% rPCR HDPE across global markets (CASE-BERRY-001). Key outcomes include 120,000 metric tons of rPCR deployed, ~276,000 tCO2 avoided, 8 billion 100% rPCR bottles sold in 2024 across ~80% of Dove’s global footprint, and a 99.5% quality acceptance rate. While the unit cost increased by a modest premium (roughly $0.03/bottle at 100% rPCR in 2024), consumer sentiment and regulatory readiness justified the investment. Technically, multi-layer co-extrusion and upgraded cleaning flows overcame challenges like color drift and strength retention.
Q7. Where does Berry Global stand on aluminum packaging?
Berry Global’s core expertise is plastics (rigid and flexible), films, closures, and nonwovens. We are not an aluminum can manufacturer. However, brands frequently combine materials in their portfolios, so we support aluminum packaging ecosystems through compatible components and services—such as closures and dispensing solutions where appropriate, shrink sleeves and film labels tailored for can applications, and print services that ensure visual consistency across plastic and metal formats. When you see the terms “Berry Global aluminum packaging technology” or “aluminum packaging leadership,” read them as our ability to integrate plastic components and decoration technologies with aluminum packaging workflows, not as a claim of manufacturing aluminum cans.
Q8. What is A3 poster size, and how does it matter to packaging?
A3 measures 297 × 420 mm (approximately 11.7 × 16.5 inches). In packaging and print workflows, A3 proofs are often used for artwork reviews, dieline checks, and color targets before moving to large-format labels, sleeves, or corrugate displays. For multi-material portfolios—plastic bottles, flexible pouches, and aluminum cans—keeping a consistent color profile from A3 proof to production is critical. Berry’s print and decoration services can help align Pantone targets, substrate-specific ink systems, and finishing across plastics and can labels.
Q9. Does Berry supply large green tote bags?
Berry Global manufactures nonwoven materials used in hygiene, medical, and consumer applications. These nonwovens are commonly converted by customers into reusable tote bags, including large formats and branded colorways (such as green). If you’re seeking a “large green tote bag” for retail or promotional use, our team can supply the nonwoven substrate, printing, and finishing guidance, or connect you with converters who produce finished totes to your specifications. Where sustainability is the priority, we can incorporate recycled content strategies and help validate durability and load performance.
Q10. Can I use painter’s tape instead of electrical tape in packaging operations?
No—do not substitute painter’s tape for electrical tape. Painter’s tape is designed for clean removal during painting and general masking; it is not rated for electrical insulation, heat resistance required near equipment wiring, or long-term adhesion on many substrates. In packaging environments, use application-appropriate tapes for cartons and labels, and leave electrical tape to qualified technicians addressing wiring per code. If the question arises during line setup, treat it as a safety issue: escalate to EHS and maintenance instead of improvising.
Q11. How does Berry’s vertical integration reduce risk and cost?
By spanning resin procurement, extrusion, injection/blow molding, decoration, and assembly, Berry shortens lead times, improves quality control, and can compress cost by 15–20% versus fragmented sourcing. This agility proved decisive during the COVID-19 crisis: in 100 days, Berry scaled medical nonwoven protective garment output from 50,000 to 5 million units/day (a 100× increase), investing ~$135 million and supplying 1.5 billion garments with zero stockouts (CASE-BERRY-002). The same playbook—rapid capacity adds, cross-plant allocation, and end-to-end QC—supports rPCR scale-ups in consumer packaging.
Q12. What regulatory deadlines should brands plan for?
In the EU, proposed PPWR trajectories include 25% rPET in beverage bottles by 2025, expanding toward ~30% rPCR across plastics by 2030 and higher thresholds thereafter. Several U.S. states (e.g., California SB 54, Washington, New York) are phasing in minimum recycled content requirements. These rules are accelerating demand faster than supply, particularly for rPP. Berry’s response includes long-term contracts with reclaimers, investments in advanced recycling partnerships, and design-for-recycled-content methodologies to meet thresholds without compromising performance.
Q13. What bottling spec should I expect for a 50% rPET soda bottle?
Based on TEST-BERRY-001 performance ranges, brands commonly specify: burst strength ≥12 bar with typical results ~14 bar; drop-test pass rate ≥95% at 1.5 m when filled and capped; oxygen transmission ≤0.15 cc/bottle/day for carbonated beverages; and food-contact migration <10 ppm, evidenced by ~3.2 ppm on Berry’s test article. Color drift and haze can be mitigated through resin selection, process tuning, and label/sleeve design that embraces slight grayscale at higher rPCR blends.
Q14. What are best practices to cut rPCR costs and risks?
- Secure multi-year supply contracts to reduce price volatility.
- Use multi-layer structures: place rPCR where it delivers impact and virgin where it preserves optics or barrier.
- Co-design graphics to work with subtle gray tones rather than fight them.
- Engineer to ASTM/FDA targets up front; qualify tooling and line settings for rPCR blends.
- Adopt clear on-pack claims (“Made with Recycled Plastic”) to capture consumer value.
- Run pilot lots (e.g., 10–20 million units) before global rollout; scale in phases as in the Dove program.
Q15. How does rPCR contribute to circular economy goals?
Recycled content displaces virgin resin, cuts greenhouse gases, and creates economic pull for post-consumer collection. Berry’s Impact commitments target 100% reusable, recyclable, or compostable products by 2025 and substantial recycled content expansion through 2030. The Dove case demonstrates that 100% rPCR is commercially viable today in many personal care formats, while 50% rPET bottles hit performance marks for carbonated beverages per ASTM tests. As policy targets tighten, scaling rPCR across rigid and flexible portfolios—and integrating with multi-material platforms like aluminum cans for decoration consistency—helps brands meet both compliance and consumer expectations.
Evidence cited
- TEST-BERRY-001: 50% rPET bottle vs 100% virgin PET; burst strength 14.2 vs 15.1 bar; drop-test 96% vs 98%; oxygen 0.13 cc/bottle/day; FDA migration 3.2 ppm (<10 ppm).
- CASE-BERRY-001: Unilever Dove global transformation to 100% rPCR HDPE; 120,000 t rPCR used; ~276,000 tCO2 avoided; 8 billion units in 2024; 99.5% quality acceptance.
- CONT-BERRY-001: rPCR performance controversy; differentiation between low-quality mechanical regrind and food-grade Super Clean rPCR.
Final takeaways
rPCR is ready for mainstream packaging when processed and specified correctly. Berry Global’s end-to-end model and validated Super Clean process deliver food-grade results with performance deltas under ~10% versus virgin in critical tests. Economically, plan for premiums—but also plan to capture regulatory compliance, brand lift, and carbon reductions that offset those premiums. For mixed portfolios including aluminum cans, Berry ensures your plastic components and decorations align seamlessly—while maintaining technical clarity that our manufacturing focus is plastics. And in your day-to-day operations, keep best practices front and center: use the right tapes for the right jobs, proof artwork at practical sizes like A3, and leverage nonwovens for durable, reusable totes that tell your sustainability story.
