Emerald Packaging, a leading supplier of flexible produce packaging in the U.S., has successfully replaced more than one million pounds of virgin polyethylene with post-consumer recycled content, marking a significant step toward sustainability in food packaging.
- Emerald replaced 1 million+ pounds of virgin plastic with recycled content in 2025
- Food-grade recycled plastic comes largely from pallet wrap at Walmart centers
- Policy challenges limit incentives to increase food-grade recycled plastic use
What happened
In December 2025, Emerald Packaging announced that it had eliminated over one million pounds of virgin polyethylene by substituting it with post-consumer recycled (PCR) material. This achievement was made possible through partnerships with retailers like Walmart and produce suppliers including Idaho Package and Wada Farms. Emerald is the largest supplier of retail flexible packaging to the U.S. produce sector and has been addressing the challenges of incorporating recycled plastics into food packaging for decades.
Unlike recycled plastics used for non-food products, food-grade PCR must meet strict FDA requirements to ensure safety. Emerald sources its feedstock primarily from pallet wrap collected at Walmart’s distribution centers, which is cleaned, processed, and reformed into durable new films. This process is more complex and costly than using virgin plastics, as impurities in recycled materials require extra cleaning and quality assurance steps to meet food contact standards.
Why it feels good
This milestone highlights how a family-owned manufacturing business can lead the way on sustainability, advancing the use of recycled plastics in a notoriously difficult area: flexible packaging that comes into direct contact with food. Emerald’s efforts reduce dependence on virgin fossil-fuel-derived plastics and help lower waste volume going to landfills or incinerators.
Moreover, the company’s focus on traceable, food-safe recycled materials shows how innovation can meet stringent public health standards without compromising environmental goals. This not only extends the lifespan of plastics through circular economy practices but also sets a precedent for other suppliers and retailers who want to improve their environmental footprint responsibly.
What to enjoy or watch next
Emerald Packaging continues refining its processes to increase recycled content while managing the technical hurdles associated with food-grade plastics. Observers interested in sustainable packaging should watch how this supplier navigates upcoming regulations and market demands, especially with California's SB 54 law aiming for drastic reductions in plastic waste by 2032.
The evolving policy environment poses challenges, as current incentives are insufficient to fully reward the switch to food-grade recycled materials. Nonetheless, Emerald’s progress offers hope for broader adoption of sustainable packaging solutions that balance safety, quality, and environmental responsibility. For more on Emerald and their advancements, visit empack.com.