In recent years, the egg box material has evolved from cardboard to EPS foam. Now is the next stage of sustainable development in packaging evolution: a box made of 100% recycled PET soda bottle. A Hickman family farm near an egg factory near Phoenix, Arizona, has just launched a new 18-cell egg box, such as Costco.
Global Plastics, Inc., a vertically integrated recycler in Perris, Calif., buys recycled PET bottles from the recycling center through the California Redemption Plan and pays the cost of recycling bottles for each consumer, with a California recovery of about 90%. Global Plastics recycles about 4 million bottles a day, classifies them in color and shape, and cleanses them according to FDA standards. The company then pellets the material and extrudes the sheet for thermoforming.
Dan Bahou, his father founded Global Plastics Co., Ltd., the company was initially used as a bottle recycling center and grew to RPET sheet to thermoformed substrate manufacturers and distributors. "We are environmentally friendly," Bahou said.
One of the problems Global Plastics faces is how to deal with green and amber PET bottles. The company's customers tend to want highly transparent RPETs.
So Bahou gave birth to an idea, RPET egg box, he recommended to Hickman's family farm. "They are like a family business and the idea of a green and amber RPET box," said the farmer, "and the color of the bottle is color, without adding color dyes."
The innovative design of the egg box includes "locking" support posts, which are located below the lid of the package to provide protection for the egg. In addition, the bottom of the egg rests in the perfect raised notch. Transparent packaging eliminates the need for customers to open the carton to check the eggs. These features also reduce egg rupture and damage.
The real benefit is that Hickman bring a second life for recycling green and amber bottles. The goal is to recycle those bottles after consumption so that they no longer enter the ocean and landfill. As the EPS recycling is difficult, therefore, Hickman is full of forward-looking.