PepsiCo Seeks Biodegradable Materials for Injection Molding and Coating

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PepsiCoPepsiCo）Looking for biodegradable, injection-moldable resin materials that can directly or nearly directly replace polyolefins (such as polyethylene (PE) and polypropylene (PP)) for injection-molded caps and other primary packaging components in direct contact with food and beverages.

Polyolefins (such as polyethylene and polypropylene) are widely used in injection molding packaging due to their excellent properties. These thermoplastic plastics have advantages such as low cost, chemical resistance, durability, and ease of processing, making them suitable for various applications including rigid containers, threaded structures, and bottle caps. However, despite their widespread use, most polyolefins are derived from petrochemical raw materials and are difficult to biodegrade, resulting in their long-term persistence in the environment and increasing concerns about plastic waste and pollution.

Currently, biodegradable and compostable materials such as polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polyhydroxyalkanoates (PHA), and thermoplastic starch (TPS) blends have been explored as alternatives to traditional polyolefins. However, many of these materials exhibit deficiencies in mechanical strength or injection molding performance. Additionally, the density of some materials exceeds 1 g/cm³, causing them to sink in water, which complicates sorting in flotation-based recycling systems. This density difference is particularly pronounced in fiber-based packaging—plastic bottle caps need to float during the pulping process for efficient separation and, in certain cases, must also be compatible with PET bottle recycling processes.

Develop a resin with a density lower than 1 g/cm³ for injection-molded bottle caps and other primary packaging components, which will simultaneously meet the mechanical performance and recycling requirements of fiber-based packaging combinations. Such materials will help PepsiCo achieve its sustainability goals: reducing reliance on fossil-based plastics, lowering environmental impact, meeting corporate targets, complying with regulatory requirements, and responding to consumer demand for environmentally friendly packaging.

Key Success Criteria

Necessary condition

Density is less than 1 g/cm³.

Compatible with fiber regeneration and/or PET recycling systems.

• Exhibits thermoplastic behavior with a melt flow index of 25-55 (ASTM D1238 standard), compatible with PE/PP injection molding grade materials.

Pathways that comply with or explicitly conform to direct food contact regulations.

Technology Readiness Level (TRL): Level 2-9

Preferred Conditions

• Derived entirely or partially from renewable materials

• Home compostable or biodegradable in soil; degradability in industrial or marine environments is a plus.

Possible solutions

• Bio-based polyester variants optimized for density (such as polybutylene succinate (PBS) or polybutylene adipate terephthalate (PBAT))

• Polyhydroxyalkanoate (PHA) composites

PLA-based blends

• Low-density thermoplastic starch (TPS) formulation

Low-density biodegradable polymers, composites, or filled systems

Resins with physical or chemical foaming capabilities

Unconcerned Plan

Materials that decompose into toxic components in anticipated disposal scenarios.

Non-biodegradable bio-based polyolefins

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PepsiCo is seeking biodegradable polymer coatings or biodegradable resins that can be applied via spraying to fiber-based beverage packaging (with a capacity of 350 ml to 1 liter). These materials should provide effective barrier properties and achieve high fiber recovery rates to support recyclability.

As part of the PepsiCo Positive (pep+) agenda, PepsiCo is committed to reducing the use of virgin plastic and enhancing the recyclability and compostability of its packaging. The beverage industry faces unique challenges as its packaging needs to be both durable and functional while meeting environmental goals. Fiber-based packaging presents a promising alternative to traditional fossil-based plastics, but it requires effective barrier coatings to ensure product protection.

For beverage bottles, the sprayed inner coating must provide high barrier performance while maintaining recyclability through fiber regeneration (fiber recovery rate >85%). Current coating technologies have limitations in simultaneously meeting these performance and sustainability goals, necessitating the exploration of biodegradable polymer resins such as PHA (polyhydroxyalkanoates) and similar materials. PepsiCo hopes to find solutions to develop fully recyclable fiber-based beverage packaging using biodegradable polymer resins, ultimately driving towards a more circular packaging economy vision.

Key Success Criteria

Necessary Conditions

The spraying process compatible with standard nozzle sizes

Water vapor transmission rate (WVTR) ≤ 0.31 g/m²/day (23°C, 50% RH); moisture loss <1% within 6 months.

Oxygen Transmission Rate (OTR) ≤ 2.0 cc/m²/day (23°C, 50% RH)

Derived from renewable resources and biodegradable.

Fiber recovery and recycling requirements in compliance with the "Voluntary Standard for the Reconditioning and Recycling of Corrugated Fiberboard and Paper-based Packaging" (FBA/AF&PA)

Technology Readiness Level (TRL): 5-9

Feasible Plan

Sprayable barrier coatings based on PHA

Biodegradable nanocomposite coating

Biodegradable resin system

Sprayable aliphatic polyester coatings, such as polybutylene succinate (PBS) and poly(butylene adipate-co-terephthalate) (PBAT) blends.

Biopolymer cross-linked network

Unfollow plan

Non-biodegradable polymer resin materials

Materials containing food contact prohibited ingredients or not complying with food contact safety regulations