Plastmore Delivers a Clear Sustainable Food Packaging Solution

Plastmore, the global brand of Üstün Plastik, is a leading manufacturer of in-mold labeling (IML) packaging solutions for the food industry. Recognized for its expertise in eco-friendly food packaging, Plastmore helps brands deliver safe, durable, and visually appealing packaging that protects products while reducing environmental impact. Thess packaging helps keep food fresh, intact, and safe for consumption and any food supply chain.

We partnered with Milliken & Company, a global manufacturing leader whose focus on materials science, and with Moldmore is a manufacturing molds, specialized in thin wall plastic containers and lids. we all together work through 20 months for a top Turkish chocolate brand to solve a major challenge: replacing their iconic polystyrene (PS) chocolate containers with a sustainable packaging alternative that preserved clarity, performance, and brand identity.

For decades, the chocolate brand relied on crystal-clear PS containers that consumers instantly recognized. However, PS packaging had significant drawbacks:

❌  Heavy and brittle: At 1040 kg/m³ density, PS packaging was prone to breakage during distribution. It is also a difficult plastic to recycle, as it is classified as non-recyclable under the Association of Plastic Recyclers’ definition.

❌  Non-recyclable plastic: Classified as non-recyclable, PS packaging created waste management issues.

❌  Sustainability concerns: With growing global demand for recyclable food packaging, continuing with PS threatened the brand’s reputation.

The key challenge: find a clear plastic packaging alternative that delivered sustainability, strength, and recyclability—without losing the visual identity consumers trusted.

Plastmore collaborated with its innovation partner Milliken & Company to develop a polypropylene (PP) chocolate packaging solution enhanced with Millad® NX™ 8000 ECO. Brand owners using PP resins clarified with Millad NX 8000 ECO can display a UL Environmental Claim Validation label on their injection-molded parts. Environmental Claim Validation provides independent validation that products live up to their environmental claims, helping increase consumer confidence and brand credibility overall.

Through 20 months of R&D, resin trials, and packaging tests, Plastmore engineered a PP packaging solution that offered:

✅ Glass-like clarity equal to PS.

✅ Stronger durability, reducing breakage during transport.

✅ Lower carbon footprint, thanks to reduced energy use during molding.

✅ Recyclability, aligning with RecyClass recyclability guidelines.

✅ IML compatibility, enabling seamless branding with sustainable in-mold labeling.

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By switching from PS to PP, the chocolate brand achieved measurable improvements:

♻️ 42% less plastic usage compared to the original PS chocolate packaging design.

⚡ Up to 10% lower energy consumption in production.

🚚 55% lighter packaging, cutting transport costs and emissions. PP packaging has a lower manufacturing carbon footprint than PS packaging. In addition, the lower weight of PP packaging—nearly 55% less than PS packaging—translates to lower transportation costs and impacts, continuing its lower carbon footprint throughout the value chain.

📉 7% fewer product losses during shipment due to improved durability. Thanks to its higher resistance to breakage.

🔄 High recyclability, supporting circular economy packaging goals. PP packaging is more readily recyclable for post-consumer use. The new PP box helps bring the value chain closer to a circular plastic packaging loop—a trend very much in line with RecyClass recyclability guidelines.

The chocolate brand successfully launched its new PP chocolate boxes across Turkey in the spring of 2024 to instant success. The resulting chocolate PP packaging made using Millan NX 8000 ECO clarified PP resin offered the chocolate brand leading sustainability benefits for reworking their packaging:

1. Strengthened sustainability credentials with a recyclable, eco-friendly food packaging solution.
2. Reduced carbon footprint through lighter weight and energy-efficient production.
3. Maintained the iconic clarity and design that consumers recognized and trusted.
4. Improved efficiency by integrating in-mould labelling IML packaging technology, reducing labor and materials.

The transition proved that sustainable food packaging can deliver both brand value and operational efficiency.

This project highlights Plastmore’s expertise as a trusted IML packaging manufacturer and innovation partner for global food brands. By replacing PS packaging with a lightweight, recyclable PP solution, Plastmore delivered a win-win: better performance, lower environmental impact, and a strong brand identity.

More brands are switching from PS to PP — a smarter, stronger, and more sustainable choice that cuts costs, boosts recyclability, and meets today’s packaging expectations. This study is a great example of PP and Milliken’s Millad® NX™ clarifier in action comes from Plastmore, according to The Material Selection Plastform SpecialChem

Plastmore continues to lead the way in sustainable plastic food packaging solutions, helping brands worldwide transition to eco-friendly, recyclable, and circular economy packaging systems. for other resources for this sustainable container

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