kp Launches UK’s First 100% Recycled Tray2Tray® Pilot with Tesco and Hilton Foods
In a groundbreaking move towards sustainable food packaging, Klöckner Pentaplast (kp) has launched the UK’s first-ever pilot for food trays made entirely from recovered tray material. Partnering with Tesco and Hilton Foods, the initiative will see Tesco’s Finest minced beef packed in kp’s 100% recycled PET (rPET) Tray2Tray® packaging—marking a major step forward in achieving circularity in food packaging.
The innovative trays, made from PET recovered through kp’s Tray2Tray® recycling initiative, will be sealed with kp FlexiLid®, a high-performance barrier film containing 30% post-consumer recycled (PCR) content. This industry-first pilot aims to set a precedent for scaling up food tray recycling, ensuring that valuable PET material remains within the food-grade packaging loop instead of being downcycled into lower-value applications.
A Game-Changer for the Circular Economy
"While this is a pilot, it’s a massive step forward for the packaging circular economy," said Rebecca Harris, Global Account Director at kp. "We launched our kp Tray2Tray® initiative to prevent food-safe tray material from being downcycled. The reality is that until demand for recycled PET trays increases, large-scale collection, sorting, and recycling won’t be sufficient. This pilot has real significance in proving what’s possible."
The challenge is clear: despite an estimated one million tonnes of PET trays being produced annually in the EU, only 5% are recycled back into food-grade trays. By developing a dedicated supply stream of recycled PET from trays, kp’s solution has the potential to significantly increase this percentage and establish a more efficient circular economy for food packaging.
Industry Leaders Backing Sustainable Innovation
The pilot has been made possible through collaboration with key industry players committed to sustainability.
Andrea Jex, Procurement Director at Hilton Foods, emphasized the importance of partnerships in driving innovation:
“This achievement exemplifies the power of collaboration with our customers and suppliers. Through these strong, long-standing partnerships, we continue to develop cutting-edge solutions that align with our Sustainable Protein Plan while ensuring quality and shelf-life standards remain uncompromised.”
James Bull, Head of Packaging and Food Waste at Tesco, reinforced the retailer’s commitment to sustainable packaging:
“We are determined to close the loop on our packaging—ensuring it is fully recyclable and contains recycled content wherever possible. Our focus remains on reducing our environmental impact and supporting customers in making sustainable choices.”
Setting a New Standard for Circular Food Packaging
Beyond launching this pioneering pilot, kp’s commitment to circularity has been recognized with its production site in Pravia, Spain, becoming the first food company to obtain the new closed-loop module within the RecyClass Traceability Certification. This certification verifies the safety, quality, and traceability of rPET used in the trays—reinforcing kp’s leadership in sustainable packaging.
Rebecca Harris concluded:
“It’s not just about being first—it’s about setting a precedent. This proof-of-concept pilot shows how kp Tray2Tray® made from 100% rPET tray flake is a seamless ‘drop-in’ solution for retailers and packers. Transitioning to sustainable alternatives should be simple, and we’re demonstrating that it can be done without compromise. This is a glimpse into the future of truly circular food packaging.”
The kp Tray2Tray® pilot represents a major milestone in advancing closed-loop recycling for PET trays—helping to reduce waste, lower carbon emissions, and drive meaningful change in the packaging industry.
