Since 1980, Churchill Container, located in Lenexa, Kansas, has specialized in creating and producing reusable and collectible drinkware and snack containers for various entertainment venues, including stadiums, arenas, restaurants, theatre concessions, convenience stores, and retail outlets.

Source: Packworld

While exploring sustainable packaging options a few years ago, Churchill discovered PureCycle Technologies and its PureFive recycled polypropylene, which is generated using a patented solvent-based purification process. In March 2024, both companies proudly announced the successful production of a PP cup containing 50% PureFive rPP resin.

Churchill's reusable cups and containers inherently provide a more sustainable alternative to single-use packaging. To further boost their environmental impact, the company offers products made from recycled materials. However, utilizing mechanically recycled PP has posed challenges. Johnson highlights two primary issues with rPP. Firstly, the melt flow of most mixed rPP is quite low, limiting its blendability at higher percentages. Secondly, purity is a concern as typical rPP often appears streaky, speckled, and can carry unpleasant odors, making it unappealing for consumers.

In contrast to rPP from mechanical recycling, PureFive rPP is devoid of impurities. PureCycle's innovative purification process involves seven meticulous steps focused on filtration and extraction to eliminate color, odor, and other contaminants from plastic waste, transforming it into ultra-pure recycled resin. In 2024, PureCycle received FDA approval through a Letter of No Objection, confirming the suitability of PureFive Ultra-Pure Recycled resin for all food-contact applications.

PureCycle predominantly sources curbside-collected and baled PP scrap from waste management companies as feedstock. Additionally, other waste plastics like PP raffia, food packaging film, and carpet fibers, typically destined for landfills, are utilized.

Moreover, PureCycle actively promotes proper disposal and collection of PP and other packaging waste through its PureZero Program, established in 2021. Christian Bruey, PureCycle's Corporate Communications & PureZero Manager, notes that the initiative initially aimed to assist professional sports organizations and entertainment arenas in improving plastic waste recycling. Currently, the Cincinnati Bengals, Cleveland Browns, and Jacksonville Jaguars are among the PureZero Program partners.

Bruey underscores the importance of implementing a "stadium pick" strategy at sports venues, where cleanup crews concentrate on segregating recyclables like plastics and aluminum from food waste to enhance recycling efforts.