rPCR vs Virgin Plastic: Berry Global’s ASTM Data, Super Clean Process, and Real‑World Proof

In packaging and printing, engineering rigor matters as much as brand promises. Berry Global operates across hard plastics, flexible films, nonwovens, and closures, leveraging vertical integration from resin processing through molding, extrusion, decoration, printing, and final assembly. That breadth gives Berry Global the unique ability to test, validate, and scale recycled plastics (rPCR) while safeguarding performance and food safety. This article examines how rPCR compares to virgin material through third‑party ASTM testing, unpacks Berry’s Super Clean process, and grounds the discussion in a five‑year commercial transformation with Unilever’s Dove. We also touch on aluminum packaging initiatives, the Bowling Green, KY operations footprint, and practical signals for packaging printing teams—including label content and flexo workflows.

Why the rPCR vs Virgin Plastic Debate Exists

Recycled plastics face a familiar skepticism in packaging: perceived strength loss, color drift, and food‑contact safety concerns. The reality is more nuanced. Process rigor—not the concept of recycling itself—defines performance outcomes. Low‑quality, lightly cleaned PCR can underperform. High‑quality rPCR, validated for food contact under FDA protocols, can meet or closely approach virgin benchmarks. Berry Global’s approach is rooted in testing under standardized methods, controlling inputs, and certifying outputs batch by batch.

ASTM D2463 Test Results: 50% rPET Bottle vs 100% Virgin PET

Independent, ASTM‑certified lab testing provides a common yardstick. In April 2024, a third‑party lab evaluated Berry Global’s 500 ml beverage bottle made with 50% rPET blended with virgin PET against a 100% virgin PET control under ASTM D2463 (and supporting standards for gas transmission and FDA food‑contact migration).

• Burst Strength at 23°C (n=50 per group): Berry 50% rPET averaged 14.2 bar (SD 0.8) with a minimum of 12.5 bar; virgin PET averaged 15.1 bar (SD 0.6) with a minimum of 13.8 bar. The Berry rPET blend is ~6% lower on average, yet comfortably above the typical >10 bar commercial threshold.
• Drop Test, 1.5 meters onto concrete, filled and capped (n=50): Berry 50% rPET had a 96% pass rate (48/50 intact), virgin PET 98% (49/50). Both meet common commercial targets (>95%).
• Oxygen Permeability (ASTM F1927, 23°C, 50% RH, 24 hours): Berry 50% rPET registered 0.13 cc/bottle/day versus virgin PET at 0.11 cc/bottle/day—still below typical carbonation‑protection targets (<0.15 cc/bottle/day).
• FDA Food‑Contact Migration (3% acetic acid simulant, 10 days at 40°C): Berry 50% rPET measured 3.2 ppm versus virgin PET at 2.8 ppm, both well under the 10 ppm threshold.

The ASTM lab summarized: Berry’s 50% rPET bottle shows minimal performance deltas relative to virgin PET (generally <10%) while meeting food‑contact safety. That outcome is not coincidental—it is the product of how rPET is sourced and cleaned.

The Super Clean Process: What Makes High‑Quality rPCR Different

Not all rPCR is created equal. Berry Global employs a multi‑stage Super Clean process designed to raise purity beyond 99.9% and achieve FDA food‑contact acceptance. The protocol is engineered to remove labels, inks, volatile residues, salts, odors, and particulates, then verify results with batch testing.

• Source control: Predominantly post‑consumer PET beverage bottles (PCR), complemented by select post‑industrial recycled streams (PIR) where traceability is strong.
• Decontamination steps: Intensive sorting, hot washing, label and adhesive removal, multi‑stage rinsing, thermal treatment, and vacuum degassing to strip volatiles.
• Food‑contact validation: Berry’s rPET streams are processed under conditions covered by FDA Letters of No Objection (LNO) and tested routinely to ensure migration remains far below the 10 ppm limit in simulant protocols.
• Co‑processing and blending: rPET pellets are co‑processed with virgin PET where design or color targets demand specific mechanical and optical properties, often at 25–75% rPET ratios, and proven up to 100% rPET in certain use cases.

When paired with good design (wall‑thickness, base geometry, and preform tuning), Super Clean rPCR yields predictable performance—evidenced by ASTM D2463 outcomes and years of commercial data in bottles, closures, and rigid containers.

Commercial Proof: Unilever Dove’s Journey from 25% to 100% rPCR

Real‑world scaling is the definitive test. Since 2019, Berry Global and Unilever’s Dove have undertaken a phased transition of HDPE bottles from 25% rPCR to 100% rPCR across global markets.

• Phase 1 (2019–2020): North American pilot at 25% rPCR; drop test pass rate of 98% (vs ~100% for virgin), minor gray tint, acceptable shelf presence, and a ~$0.02 per bottle cost increase that Unilever absorbed to deliver sustainability value.
• Phase 2 (2021–2022): Increased to 50–75% rPCR with multilayer co‑extrusion (outer rPCR aesthetics, inner layer tuned for mechanicals), further color optimization, and label redesigns that embraced a subtle gray “eco” tone.
• Phase 3 (2023–2024): Demonstrated 100% rPCR HDPE in Europe, including Ocean Bound Plastic sourcing (collected within 50 km of coastlines in Indonesia and the Philippines), processed under Super Clean for salt and contamination removal, then scaled globally to ~80% of Dove’s markets in 2024.

Five‑year outcomes: roughly 12,0000 metric tons of rPCR deployed (the equivalent of about 6 billion plastic bottles recovered), an estimated 276,000 metric tons of CO₂ emissions avoided, more than 4 billion bottles supplied with 99.5% quality conformance, and near‑zero stock‑outs. Market research indicates a positive consumer response to clear “Made with 100% Recycled Plastic” messaging, with more than half of surveyed buyers signaling willingness to pay modest premiums when sustainability is evident.

Addressing the Controversy: Performance and Safety Are About Process, Not Ideology

The industry debate often splits into two camps: one claiming rPCR is comparable to virgin; another warning of contamination and weaker performance. The most accurate position is procedural: high‑quality, properly decontaminated rPCR can meet demanding use cases; poorly processed rPCR should not be directed to sensitive applications.

• Contamination risk is real when source streams are mixed or inadequately cleaned. Berry mitigates this with strict feedstock control and the Super Clean method validated for food contact.
• Performance deltas exist but are often small when design and processing are optimized. In Berry’s ASTM data, burst strength difference was ~6%; drop‑test pass rates differed by 2%; oxygen ingress remained below carbonated beverage thresholds.
• Batch variability is controlled via traceability, repeated migration testing, and quality‑management systems that reject out‑of‑spec lots. Berry’s documented rate of customer complaints in high‑volume bottle programs remains well under 0.01%.

If you need a visual metaphor, consider the viral “banana with duct tape” art installation. Adhering a banana to a wall is intentionally rudimentary—an adhesive stunt. Food packaging is the opposite: it requires quantified tensile and impact resistance, validated migration safety, and repeatable process control. Berry’s testing, certifications, and ongoing commercial results demonstrate engineering rigor over duct‑tape improvisation.

Beyond Plastics: Aluminum Packaging Initiatives and Lightweighting

While plastics constitute Berry Global’s broadest portfolio, the company also supports aluminum packaging initiatives—particularly in lightweight aerosol formats and closures where recycling loops are well established. The focus is on design for recycling, minimized wall thickness without sacrificing performance, precise neck finishes, and labeling/printing approaches that avoid contamination of the metal stream.

• Leadership initiatives include pairing aluminum formats with high‑recycled content where feasible, optimizing geometry for mass reduction, and integrating labeling that preserves downstream recyclability.
• In printing, flexographic and digital workflows ensure precise ink laydown and curing tailored for metal substrates while minimizing energy use and waste.

These aluminum efforts complement Berry Global’s larger circular economy roadmap—using material science to drive packaging that protects products efficiently, then returns cleanly into recovery streams.

Operations Footprint: Bowling Green, KY and Vertical Integration in Practice

Berry Global’s vertical integration is enabled by a global network of plants. In the United States, facilities such as Bowling Green, KY contribute to closure molding, assembly, and decoration capacity that syncs with bottle and film production elsewhere. Having closures, bottles, and label printing aligned within one system reduces changeover times, simplifies procurement, and can lower total landed cost by 15–20% compared with dispersed sourcing.

• Co‑location and synchronized scheduling cut freight and lead‑time risks.
• Shared quality frameworks ensure caps, pumps, bottles, and labels meet common standards for migration, torque, impact, and shelf durability.
• Printing lines configured for both rigid and flexible formats enable consistent branding across caps, bottles, shrink sleeves, and cartons.

Bowling Green, KY is a tangible example of how local execution connects into global supply reliability—especially for high‑volume CPG programs where 0 stock‑outs and on‑time delivery are mandatory.

Packaging Printing Notes: Flexo, Labels, and Practical Content

For packaging printers, flexographic processes remain a backbone for labels, sleeves, and flexible films. Berry Global’s teams often run “Flyer Flex” style campaigns—rapid, iterative flexo trials to nail color, registration, and scuff resistance before market rollouts. In consumer packaging, small content decisions on labels and sleeves have outsized impact on usability and sustainability.

• Readable care information: QR codes can link to high‑utility guides, such as “how to clean Keurig one cup coffee maker,” reducing paper inserts and empowering consumers post‑purchase without cluttering primary panels.
• Recycling transparency: Clearly stating “Made with Recycled Plastic” or recycled content percentages improves consumer trust and drives recovery behavior.
• Ink and adhesive choices: Select inks and pressure‑sensitive adhesives that are APR‑recognized or designed not to contaminate recycling streams—aim for clean separation during wash cycles.

These pragmatic choices strengthen both user experience and end‑of‑life outcomes, aligning printers and brand owners with circular economy goals.

Cost, Carbon, and Compliance: The Hidden ROI of High‑Quality rPCR

It is honest to acknowledge that rPCR often carries a price premium versus virgin resin due to collection, sorting, and decontamination costs. Market data shows rPET premiums of ~20–30% and rPE premiums higher in many regions. However, when factoring carbon reductions, policy compliance (e.g., EU PPWR targets for recycled content), and measurable brand equity gains, total ROI is favorable for many brands.

• Carbon footprint: In a scenario of 1 billion 500 ml bottles, switching from 100% virgin PET to a 50% rPET blend can cut CO₂ by ~33%, translating to tens of thousands of tons of avoided emissions annually.
• Policy insurance: Building rPCR use ahead of regulatory deadlines reduces risk of fines and last‑minute supply shocks.
• Consumer signal: Surveys show that clear recycled‑content claims increase brand favorability and can offset modest per‑unit cost deltas.

Berry Global’s scale—across procurement, processing, and printing—helps compress premiums through multi‑year contracts, chemistry partnerships (including advanced recycling routes), and process efficiencies. That system‑level approach is what allows rPCR to reach parity in real‑world packaging performance while moving total cost toward competitive territory.

Takeaways for Packaging Engineers and Printing Teams

• Use standardized tests: Anchor rPCR decisions in ASTM protocols (e.g., D2463 for burst strength, F1927 for gas transmission) with sample sizes sufficient to reveal true variance.
• Prioritize decontamination: Super Clean processes with FDA food‑contact validation are decisive for bottles and rigid food packaging.
• Design for success: Adjust thickness, geometry, and preform/cycle parameters to compensate for small mechanical differences with rPCR.
• Control aesthetics early: Expect subtle color shifts at higher rPCR content; tune inks and label designs accordingly.
• Leverage integrated supply: Align bottle, closure, and label lines (e.g., via Bowling Green, KY) to reduce lead time and assure conformance.
• Consider aluminum when it fits: Lightweight aerosol formats and metal closures with recycled content can be powerful complements in a circular portfolio.
• Print with purpose: Flexographic strategies like “Flyer Flex” pilots can accelerate color accuracy and abrasion resistance while minimizing waste.

Conclusion

The rPCR vs virgin plastic discussion has moved past opinion to evidence. Berry Global’s ASTM data shows modest performance deltas (generally <10%) in 50% rPET bottles that still meet commercial thresholds, with oxygen ingress below carbonation requirements and FDA migration safely within limits. Commercial programs like Dove confirm that 100% rPCR is achievable at global scale with strong quality metrics and positive consumer responses. Viewed holistically—across plastics and aluminum initiatives, integrated operations in locations like Bowling Green, KY, and practical printing tactics—the path forward is not a “banana with duct tape” workaround; it is a disciplined, test‑backed, supply‑chain‑synchronized system that makes circular packaging real.