Applicability of bio-based polymer packaging in the meal kit context - A case study with HelloFresh

Abstract: Bio-based plastics are increasingly considered as sustainable alternatives to fossil-based plastics. Up until now, their application in the food packaging industry has been limited. The purpose of this study is to investigate the applicability of bio-based polymer packaging films for bakery products, herbs and spices in the meal kit industry context and to assess their contribution towards a more sustainable packaging approach. Six different bio-based packaging film types (starch-based, cellulose based, polylactic acid (PLA), polyhydroxyalkanoates (PHA), bio-based polyethylene (BioPE) and bio-based polybutylene succinate (BioPBS) were compared regarding their product compatibility under current HelloFresh specific supply chain conditions. Except for PHA and BioPBS, all materials can be applied for herbs, while bakery and spices are only compatible with high-barrier cellulose-based films. Additionally, BioPE is applicable for bakery products, if they are stored at frozen conditions. The environmental impact was evaluated based on a beginning-of-life (BoL) and an end-of-life (EoL) assessment. In terms of BoL, bio-based polymers outperform their fossil-based counterparts. BioPE presents a global warming potential as low as -1,6 kgCO2eq/kg polymer, compared to 1,9 kgCO2eq/kg polymer for fossil-based PE and bio-based PHA reveals the lowest cumulative energy demand of 1,1 MJ compared to 69 MJ for PET amongst the fossil-based. As to the EoL, the most frequently intended EoL scenario is industrial composting, which was identified to be unrealistic: France is the only country, amongst Germany, the Netherlands and the UK, where composting plants are compatible with bio-plastics. Similarly, none of the countries provide designated recycling streams for bio-plastics. BioPE is preferred as a recyclable option. However, if excessive food contamination residues avert recycling, cellulose-based films are recommended as a compostable alternative.