PET Thermoform Recovery Hits Record 264 Million Pounds in North America, NAPCOR Reports

The National Association for PET Container Resources (NAPCOR) has released its first standalone PET Thermoform Market Analysis, reporting that PET thermoform recovery in the United States and Canada reached a record 264 million pounds in 2024. The annual study examines production, recovery, recycled-content use, and policy developments affecting PET thermoform packaging across North America.

PET thermoforms, which include trays, cups, clamshells, tubs, and other food packaging formats, are widely used throughout the consumer goods sector. Common applications range from fresh produce and bakery products to prepared meals and beverages. According to NAPCOR, the packaging format remains an important part of food distribution due to its protective properties and transportation efficiency.

The report indicates that the 264 million pounds recovered in 2024 represents the highest volume recorded since NAPCOR began tracking PET thermoform recovery. The figure includes material collected for domestic recycling as well as exports sent for reclamation. Higher concentrations of thermoforms in curbside PET bale streams contributed to the increase.

The findings provide a detailed snapshot of a sector that is experiencing growing pressure to improve circularity while navigating challenging market conditions. Although collection volumes continued to rise, the use of recycled content in new thermoform production declined, highlighting a widening gap between recovery and end-market utilization.

NAPCOR said the results underscore the need for continued investment in recycling infrastructure and stronger domestic markets for recycled PET. The report comes at a time when the North American PET recycling industry is facing reduced domestic recycling capacity, increased imports of recycled PET, and ongoing volatility in recycled materials markets.

“PET thermoforms continue to play an essential role in protecting food, reducing waste, and delivering products safely to consumers,” said Laura Stewart, Executive Director of NAPCOR. “Our analysis shows encouraging growth in recovery while also highlighting the infrastructure, market, and policy challenges that must be addressed to further improve circularity.”

Among the report’s key findings, thermoform converters in the United States and Canada purchased more than 2.05 billion pounds of PET feedstock during 2024. Virgin PET accounted for 79% of total feedstock purchases. Meanwhile, the share of post-consumer recycled PET declined to 12%, down from 18% in 2023.

Food packaging remained the largest end-use market, representing approximately 79% of reported PET thermoform sales. However, the report found that recycled-content adoption continues to be concentrated largely in non-food and non-medical applications, where regulatory requirements are less restrictive.

The analysis also found that most recovered PET thermoforms continue to be processed alongside PET bottles rather than through dedicated thermoform recycling systems. Dedicated post-consumer thermoform material accounted for less than 1% of feedstock used in the manufacture of new PET thermoforms.

Advances in sorting technology are helping improve recovery rates. NAPCOR highlighted the growing deployment of artificial-intelligence-enabled optical sorting systems capable of identifying and separating thermoform packaging more effectively within material recovery facilities. Nevertheless, contamination, processing losses, and limited dedicated recycling infrastructure remain significant barriers to higher recycling rates.

The report arrives as policymakers across North America continue to expand recycled-content requirements and Extended Producer Responsibility (EPR) programs aimed at increasing packaging circularity. NAPCOR noted that a clearer understanding of collection systems, processing capabilities, and end-market demand will be increasingly important as these policies are implemented.

The study also reviews developments in chemical recycling, industry consolidation, and ongoing investments designed to strengthen domestic recycling capacity and improve material recovery outcomes.

“PET thermoform manufacturers are a critical segment of NAPCOR membership and the PET value chain,” said Tom Busard, NAPCOR Board Chair, Chief Polymers and Recycling Officer for Plastipak Packaging, Inc., and President of Clean Tech. “Continued circular progress for this packaging will require investment in collection and processing infrastructure, technological innovation, and policies that recognize both the recyclability of PET packaging and the realities of today’s recycling systems.”

NAPCOR said the analysis is intended to support policymakers, recyclers, brand owners, packaging manufacturers, and sustainability professionals as they evaluate strategies to increase PET thermoform circularity across North America.

Source: NAPCOR

SUNSHINE Spotlight: PET thermoform recovery reached a record level in 2024, but declining recycled-content use highlights ongoing challenges in converting recovered material into new packaging applications.