Food Grade Recycled Polypropylene (rPP)

This ground-breaking project has shown that a food grade recycled PP resin derived from post-consumer sources can be achieved using a patented process. The resulting material can be used at 100% levels in contact with food.

Nextek was commissioned by WRAP to work in partnership with the UK packaging supply chain, retailers, brand owners and the recycling industry to develop a viable process to recycle household Polypropylene (PP) packaging waste into recycled PP (rPP) approved for use in the manufacture of food packaging.

Focus was on developing a recycling process that could increase the decontamination performance to the standards required by EU regulations for food contact and that could cope with a wide range of PP packaging materials encountered in the post-consumer PP packaging stream.

Recycling a wide range of mixed rigid post-consumer PP packaging to food contact quality is more complex than the recycling of HDPE and PET bottles. Nextek approached this challenge by identifying and selecting a process that provides a high level of melt-phase decontamination in an extruder with a specially designed vacuum section that provides a large surface area for removal of volatile contaminants, followed by treatment in a heated high-vacuum degassing reactor.

This project demonstrates the development of full scale processes that can expand the recycling of plastic packaging to include rigid PP packaging along with HDPE and PET packaging in a closed loop system. Retailers and brand owners have supported the development of this technology because it has direct environmental benefits such as lower carbon footprint packaging, resource efficiency and diversion of packaging waste from landfill.

Further investigations by Nextek are focusing on improved automated sorting and separation of PP food packs from packs previously in contact with non-food substances. Nextek is now running large scale rPP trials and working with a number of packaging manufacturers to trial turning rPP resins into a variety of moulded and thermoformed pots, tubs and trays.

Black Plastics

Working with industry partners Nextek has developed an alternative colour system that maintains the integrity of black packaging but can still be identified and separated. This has the potential to save 30,000 tonnes of packaging from landfill.

This ground-breaking project aims to facilitate the development of technical solutions for the recovery and recycling of rigid black plastic packaging from a mixed plastic waste stream. The R&D project was commissioned by WRAP and focuses on delivering environmental benefits over existing waste management options.

 Common black pigments cannot be sorted by most Material Recovery Facilities (MRFs) and Plastics Recovery Facilities (PRFs). The key objective is for these alternative colourant techniques to allow recyclers to sort black packaging in existing mixed plastics sorting facilities.

A small number of colourants were selected in order to evaluate these key principles, which will be equally applicable to all suppliers.

The results show the economic benefits arising from the recycling of up to an estimated 60,000 tpa of black plastic  that could include electrical and electronic equipment (EEE), automotive and building/construction industries. A range of detectable black colourants are now available that allow the automatic detection and recovery of these materials to be reused as substitutes for virgin plastics avoiding landfill.

Recycled polyethylene terephthalate (rPET)

Nextek has been instrumental in improving the technical performance of a number of PET recycling operations within Europe, USA, South America, Asia, Africa and Australasia.

The key issues often found in PET are PVC contamination, black specks, discolouration, metals, coloured PET and other plastics.

There are many technical and composition aspects that contribute to the production of high-quality food grade PET flakes and pellets. Nextek’s decades of experience in the design and operation of PET recycling operations enable us to rapidly pinpoint the ways of improving the existing processes and overcoming the root cause of deterioration in product quality.

Nextek can assist in in-plant trouble shooting, technical and economic feasibility studies and the specification of up-to date technologies and equipment. Our expertise can significantly improve the key quality parameters of PET flakes and pellets ensuring that we meet customer expectations as well as the complex regulatory requirements of USFDA and EFSA.

Nextek has the skills and experience to audit existing recycling operations for brand owners and retailers to ensure compliance with supply specifications and food contact requirements in the country of operation.

Food Grade Recycled High Density Polyethylene (HDPE)

Closing the loop by recycling milk bottles back into milk bottles provides recyclers with additional commercial benefits, brand owners with sustainable packaging and consumers with improved environmental outcomes.

Technology for closed loop recycling of post-consumer HDPE has been developed by Nextek as part of a WRAP funded project in 2005, and has now been commercialised in the UK.

This ‘super cleaning’ process produces pelletised rHDPE approved for food contact applications. This reduces our reliance on virgin HDPE and has significant environmental benefits.

The technology uses a process and equipment similar to what has previously been used for food grade rPET and is well suited to operating in a current food grade rPET plant as a second stream of material.

The UK commenced using rHDPE at 10% addition rates and has since moved to 15% in an industry wide initiative. Targeting 30% addition rates by 2015 the recovery level and closed loop recycling of milk bottles has continued to grow in the UK to meet the increased demand of this now valuable commodity.

Nextek continues to develop and expand this new technology in many other countries providing new opportunities and improved sustainability outcomes for business and the community.

Nextek has also completed work on Australia’s first food grade rHDPE plant in Sydney Australia. This plant was designed by Nextek to produce high quality food grade rHDPE and food grade rPET to optimise the value of the in-feed material.

NextCupCycle resin

NextCupCycle is a subsidiary company to Nextek Ltd that focuses on recycling complex waste streams such as plastic paper laminates.

NextCupCycle manufactures everyday products from complex waste streams such as paper plastic laminates. NextCupCycle has been developed following years of research on paper plastic composites with specifically designed resins and formulations to meet a variety of property requirements.

The launch material for NextCupCycle resin is based on coffee cups that do not have an end of life option. Millions of takeaway paper coffee cups are sent to landfill because, until now, an end of life solution has not been possible.

NextCupCycle work with Ashortwalk on the rCUP to produce the full circular solution:



A recent survey asked consumers about coffee cup recycling.

61% of consumers claim they want to recycle their cups but are struggling in the current environments and 88% of consumers said recycling should be more consumer friendly.

This is where NextCupCycle and their team provide a solution. Just 43% of consumers could answer if coffee cups are recycled (sorry but I don’t quite understand this statement?). 100% of the public loved to see the products that NextCupCycle resin produced and would love to see more of this.

 Please contact us regarding your waste enquiries and recycle your coffee cups.