Combating Plastic Pollution with Recyclable Milk Powder Sachets

From recyclable packaging innovations to collaborative efforts in combating plastic pollution, a New Zealand dairy cooperative spearheads a shift toward sustainability in the dairy industry. By introducing recyclable mono-material milk powder sachets, the company is aligning its operations with the circular economy while addressing challenges in waste management across the Asia-Pacific region.

Fremont, CA: Packaging is critical in delivering safe, high-quality food to consumers, but its environmental impact is a growing concern. The APAC region faces a significant waste management challenge, generating 64 percent of the world’s mismanaged waste. Flexible plastic packaging, commonly used for food products, contributes substantially to this issue.

Recognizing this, a dairy cooperative in New Zealand is taking bold steps to revolutionize its milk powder sachets by shifting to recyclable packaging materials. This move aligns with the company’s commitment to sustainability and addressing plastic pollution, particularly in the Asia-Pacific (APAC) region.

These milk powder sachets, designed with high-barrier laminated foil plastic, have traditionally been effective in preserving product quality. However, these multi-layered structures—comprising up to 11 layers of different materials, including aluminum—are challenging to recycle.

A Shift to Mono-Material Packaging

The Fonterra Research and Development Centre (FRDC) has collaborated with packaging suppliers to develop innovative mono-material structures that are easier to recycle while maintaining the performance standards required for milk powders. These new recyclable sachets are designed to meet the region’s evolving recycling infrastructure, ensuring compatibility with future systems.

The rollout of these recyclable milk powder sachets is already underway, with some markets adopting the new packaging. Over the next 12 months, this initiative is set to expand across the APAC region.

Balancing Performance, Cost and Sustainability

Transitioning to recyclable packaging has not been without challenges. Maintaining the shelf life of milk powder—a highly sensitive product—was a top priority. Fonterra conducted rigorous testing and optimization to ensure the new materials perform as effectively as traditional sachets on high-speed production lines.

Another factor in the shift has been the cost. Mono-materials are initially more expensive to produce than conventional laminated packaging. However, regulatory frameworks like Extended Producer Responsibility (EPR) programs will help offset these costs. As the industry adopts recyclable materials more widely, economies of scale and technological advancements are expected to decrease prices.

Tackling Plastic Pollution Systemically

Recyclable packaging is part of a broader effort to combat plastic pollution. The cooperative recognizes that solving this issue requires collaboration across multiple sectors and nations in the APAC region. By contributing to developing a circular economy, Fonterra aims to redefine how packaging is managed at the end of its life cycle.

This approach involves working with governments, recycling organizations and other stakeholders to improve collection and processing systems for post-consumer plastics. The goal is to turn discarded packaging into valuable raw materials for new products, reducing reliance on virgin plastics.