Recycling

HolyGrail 2030 – PP Flexible Belgium

Belgium is the first country in Europe to test the sorting and recycling of crisp packets into new food packaging.

Objective

Through digital watermarking and advanced recycling, this project aims to demonstrate that food-grade recycled PP from used flexible packaging is technically feasible, ecologically sound and economically viable. 

Context

Innovation and digitalisation are important drivers in the circular economy. A great many advanced technologies are already deployed in the sorting centres to separate packaging materials, including robots and infrared cameras. And some packaging does not end up in the right stream because it cannot be optimally detected. It is also becoming increasingly important to make a distinction between food and non-food packaging.

Approach

By 2030, the European PPWR (Packaging and Packaging Waste Regulation) will require food packaging to contain at least 10% recycled material. Flexible polypropylene (PP), think crisp packets, snack packaging and plastic films, represents the biggest challenge in this regard. The current system cannot distinguish between flexible food packaging and non-food packaging. As a result, there is currently no approved route to reprocess recycled flexible PP into food packaging. This project is therefore not building on an existing system: it is creating an entirely new material stream. 

Belgium is taking a pioneering role as the first country in Europe to run a large-scale real-world test with flexible packaging that is actually placed on the market and used and discarded by consumers. This is a deliberate choice: in real-world conditions, packaging is folded, damaged or contaminated. Only in this way can we determine whether the technology also works in practice. 

The project is part of HolyGrail 2030, an international programme involving some 75 participating companies and organisations, facilitated by AIM.

The project unfolds in five steps:

  1. Marking the packaging — Flexible PP packaging for snacks and food products is fitted with an invisible digital watermark and brought to the Belgian market through regular distribution channels. (completed / ongoing)
  2. Smart sorting — After collection via the PMD bag, specialist cameras at the sorting centre detect the digital watermark. This allows food packaging to be automatically separated from non-food packaging. Sorting trials begin on 23 June at Hündgen Entsorgung in Swisstal, Germany.
  3. Testing recycling — The sorted food-grade PP stream is processed through several advanced recycling processes. (planned Q4 2026)
  4. Producing new films — New films are produced from the recyclates to test whether they are suitable for existing packaging applications. (planned December 2026 – January 2027)
  5. Evaluating food safety — The recyclates and films are tested for compliance with European food safety guidelines (EFSA). (planned Q1 2027) 

Partners

  • PepsiCo
  • Mondelēz International
  • Ferrero
  • Pladis
  • Hündgen Entsorgung
  • Digimarc
  • Pellenc ST
  • Fost Plus
  • AIM

Duration

  • Smart sorting: starts 23 June 2026
  • Recycling tests: Q4 2026
  • Film production: December 2026 – January 2027
  • Food safety evaluation: Q1 2027
  • HG2030 final report: 2027
  • Fost Plus evaluation & decision: 2027
  • Full implementation: 2029 

Results

The findings will be brought together in the HG2030 Final Report, covering insights on sorting efficiency, suitability of the recyclate for food packaging, and economic viability. Initial findings are expected in H2 2026, with the full report due in 2027.