Sustainability Awards Finalist Interview: Thermapet’s process delivering recyclable containers

You’re a finalist in the Sustainability Awards 2026. Congratulations! To start off, could you summarize your entry in less than 50 words?

A patented process that may be integrated into existing thermoforming machines to take conventional 100% pure PET sheet as input and stretch it in two dimensions (no chemical additives), delivering fully recyclable containers with temperature stability from -40°C to 220°C, a higher oxygen barrier and superior sealing properties.

Why do you think the judges were impressed with your entry? Tell us about what is innovative about your process.

The utilization of existing PET plastic, for which extensive recycling lines are currently operational (for PET bottles), means that thermoformed containers produced using the Thermapet process not only meet high heat temperature stability requirements but seamlessly fit into recycling streams without the need to establish new infrastructure. Consequently, the environmental benefits are immediate and all at a reduced cost of production!

For this reason, the barrier to adoption for established converters is relatively low. There is no new resin to qualify, no novel-substance food-contact approval required and no need for further migration testing. The converter buys the same APET sheet from their existing suppliers, runs the same thermoforming machine, and keeps the same filling, sealing and lidding downstream. Thermapet adds one process step, delivered as a retrofit module on an installed thermoforming line or as a turnkey line for new capacity. The addressable market is substantial: more than 30 million tonnes a year of trays, lids and cups for high-temperature packaging are produced on approximately 25,000 thermoforming lines. Today, all of this packaging comprises non-sustainable, non-circular materials ending up in landfill, incinerators or our oceans.

Retrofitting existing machines is possible because we do not need the two-mold hot and cold arrangement the industry associates with CPET (currently the only plastic material stable up to 220°C). We run a standard cold mold system and crystallize the PET by physically stretching the plastic sheet under temperature control. Since we deploy a physical, rather than chemical, process the resultant crystallized PET remains 100% pure and so may be recycled through existing bottle-to-bottle infrastructure downstream and then reused as raw feedstock for the production of new containers.

Technically, the process does more than widen the temperature window. It also induces a higher oxygen and water vapor barrier and delivers markedly enhanced sealing properties.

This combination of enhanced properties make Thermapet processed products ideal for conventional modified atmosphere packaging, “MAP”. Instead of producing a multilayer barrier structure, a converter can run a mono-PET tray straight into a standard MAP format to generate extended shelf life but with no EVOH, laminate or barrier film that are otherwise required with existing technology. The pack stays mono-PET and fully circular with a lower cost of production.

The sustainability case is compelling. Frozen supply chains may be moved to chilled without compromising shelf-life which reduces energy demand in the logistics chain. Moreover, shelf-life may be extended for traditionally chilled products both eliminating food waste and cutting costs for distributors and retailers. Based on our most conservative forecast model, Thermapet processed packaging will mitigate 50 million tonnes of CO₂e cumulatively by 2037, which is approximately the annual CO₂ output of 11 million cars, with food waste alone accounting for 27 million tonnes.

There are further benefits beyond carbon. Thermapet containers can remain transparent, where CPET is necessarily non-transparent. Such transparency provides substantial benefits in sorting within recycling lines.

Whilst CPET is the only incumbent technology offering stability to 220°C (Oven safe), the larger market is for microwave stable containers requiring heat stability to 120°C. This market is currently serviced by polyolefin-based plastics (typically Polypropelene “PP”). Such plastics are non-recyclable, single use products. Thermapet processed pure PET can readily replace such packaging delivering full circularity and compliance with the emerging PPWR regulatory requirements.

As with CPET lines, PP thermoforming lines may be fitted with Thermapet modules as feeder stations to the existing line. This provides converters with an effective and efficient upgrade path. At full conversion of the current production base, with pure PET material running many mechanical loops before it needs depolymerizing, less virgin resin would be produced globally than the volume being recycled and put back into use – a win for converters, food producers, brand owners and the environment!

Finally, can you tell us about the ongoing development of your project, and what the next steps are in commercialization?

Thermapet has a proof-of-concept thermoforming line running in Bangkok which can produce sample product for testing and validation. Several converters including the 40 largest players in the market have received samples and have verified that the Thermapet process functions as specified. Moreover, sample trays have been submitted to independent testing laboratories to validate all claims including food safety certification from SGS, Singapore.

Our machinery partner is building a production scale thermoforming machine with the Thermapet process fully integrated. The first machine is expected to be completed by the end of 2026 with customer orders deliverable by mid-2027. Initial supply capacity will be 120 machines per year.

With inquiries already exceeding 500 machines, the immediate challenge for Thermapet is to work with partners to scale volume production of machines. To this end we have proposals from two module manufacturers (each with app 120 machine per year capacity) that are ready to engage. Subject to Thermapet concluding its current capital raising, we will have the necessary funds to execute these development projects which should see module availability by Q3 2027. These modules have been designed to be interfaced to existing thermoforming lines so that converters have the option of purchasing a brand new, fully integrated line or upgrading an existing line with a retrofit module.

Ultimately, we plan to license the retrofit module design to other machine manufacturers so that they can integrate our designs into their own platforms and offer turnkey Thermapet solutions as original equipment manufacturers (OEMs).

Whilst establishing robust and diverse machine supply lines is our first priority, in parallel we have been progressing some very interesting initiatives with converters who are keen to exploit the unique features of Thermapet containers beyond the core temperature stability properties.

One of the most exciting projects on our development roadmap is a joint venture with Royce Universal in Thailand and Polyplex, a very prominent film manufacturer, to develop special BOPET sealing films. On burst pressure we have already achieved 1.8 bar with 30-micron lidding, and 2.4 bar should be reachable at 40-micron. Combined with modified atmosphere packaging, we have the potential to introduce a completely new packaging category called, Modified Atmosphere High Pressure Packaging, “MAHPP”. By raising the internal oxygen or nitrogen pressure, the shelf life of packages foods increases.

The impact of this development is significant. Current multilayer barrier formats would become obsolete; supply chains that run frozen today may transition to chilled logistics, and chilled distribution may transition to ambient temperature. Retailers and brand owners will benefit enormously from the resultant reduction in distribution costs and food spoilage and there will be further environmental benefits pursuant to the associated reduction in CO₂ emissions.

The winners of this year’s Sustainability Awards are due to be announced on the 11^th November at the Sustainable Packaging Summit, taking place from the 10^th-12^th November in Utrecht, Netherlands. The Summit mobilizes leaders of the FMCG value chain, policymakers, NGOs, recyclers and investors to collaborate, remove barriers and identify opportunities on the road to sustainable transformation.

To learn more or register, visit: https://www.packagingsummit.earth

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