NAPCOR Publishes Report on North American PET Thermoform Market

Why It Matters

The data highlights a widening gap between collection growth and recycled‑content use, signaling urgent need for investment and policy action to keep North American PET packaging recycling viable and reduce reliance on virgin resin.

Key Takeaways

• 264 million lb PET thermoforms recovered in 2024, record high
• Virgin PET 79% of feedstock; rPET use dropped to 12%
• Dedicated thermoform recycling streams under 1% of feedstock purchases
• Food packaging drives ~79% of PET thermoform sales
• NAPCOR calls for policies and investment to boost domestic PET recycling

Pulse Analysis

The 2024 PET thermoform market analysis from NAPCOR underscores a pivotal moment for North American packaging. Recovery volumes have reached a historic 264 million pounds, reflecting stronger curbside participation and higher fractions of thermoforms in PET bales. This growth, however, masks a structural imbalance: virgin PET still dominates feedstock purchases, and the share of post‑consumer recycled PET (rPET) has slipped from 18% to 12% year‑over‑year. The limited adoption of recycled content is especially pronounced in food‑contact applications, where performance and regulatory constraints often favor virgin resin.

Industry stakeholders face a confluence of challenges that could stall progress. Dedicated thermoform recycling streams remain virtually nonexistent—less than 1% of feedstock purchases—forcing most recovered trays, clamshells and tubs into mixed bottle recycling streams. This dilutes the material’s value and hampers the development of specialized processing infrastructure. At the same time, domestic recycling capacity is eroding, while imports of foreign‑produced rPET increase, creating economic pressure on U.S. and Canadian recyclers. Policymakers are responding with extended producer responsibility (EPR) proposals and recycled‑content mandates, but without clear standards for food‑grade thermoforms, compliance remains uncertain.

Looking ahead, the pathway to a more circular PET thermoform ecosystem hinges on coordinated investment and innovation. Chemical‑recycling technologies promise to convert mixed or contaminated thermoforms into high‑quality feedstock, potentially expanding the supply of usable rPET. Simultaneously, targeted legislation that recognizes the recyclability of PET trays and establishes clear recycled‑content targets could drive demand for domestically processed material. NAPCOR’s suite of resources, including industry guidelines and a new white paper, aims to align manufacturers, recyclers and regulators around these goals, positioning the sector for sustainable growth despite current headwinds.