HolyGrail Project Advances Recycling of Snack Packaging into Food-Grade Materials
The HolyGrail 2030 initiative, backed by major companies including PepsiCo, Ferrero, and Mondelēz International, is set to enhance the recycling of polypropylene snack packets into new food packaging. This project aims to leverage digital watermarks and advanced recycling technologies to establish the viability of food-grade recycled polypropylene sourced from flexible packaging.
Current recycling systems struggle to differentiate between flexible food and non-food packaging, which complicates the reprocessing of recycled materials back into food-grade applications. Despite advancements in sorting technologies, such as robots and infrared cameras, many packages still end up misclassified, highlighting the need for improved sorting capabilities.
The HolyGrail project aims to create a new material flow that aligns with the Packaging and Packaging Waste Regulation, which mandates that food packaging must contain at least 10% recycled material by 2030—a challenge particularly relevant for flexible polypropylene.
Facilitated by AIM, the European Brands Association, the project also includes partners like Pladis, Hündgen Entsorgung, Digimarc, Pellenc ST, and Fost Plus. Currently, flexible polypropylene packaging is being printed with digital watermarks and distributed in Belgium. Once collected, the packaging will undergo sorting trials at Hündgen Entsorgung’s facility in Germany, where specialized cameras will identify the digital watermarks to separate food from non-food packaging.
Beginning in Q4 2026, the food-grade polypropylene stream will be tested using various advanced recycling technologies, with the goal of producing new films suitable for existing packaging applications by early 2027. These recyclates will also be evaluated for compliance with European Food Safety Guidelines (EFSA).
The findings from this initiative will be compiled in the HolyGrail 2030 Final Report, expected next year, which will provide insights into sorting efficiency, recyclate suitability, and economic feasibility. Fost Plus plans to make an evaluation and decision regarding implementation in 2029.
Belgium will be the first country to conduct a large-scale field test of this technology, assessing its effectiveness in real-world conditions where packaging may be folded, soiled, or damaged. Last year’s discussions among industry leaders highlighted the success of previous sorting trials, achieving over 90% detection efficiency.
Additionally, the Flexible Plastic Fund has launched the FlexCircular initiative in the UK, aiming to recycle up to 400,000 tonnes of post-consumer flexible packaging by 2030, further emphasizing the industry’s commitment to sustainability.