How Mondelēz is Manufacturing Circular Packaging

Mondelēz International is introducing a new flexible wrapper for its Marabou chocolate brand using chemically recycled plastic.

Developed in collaboration with LyondellBasell (LYB), Taghleef Industries and Amcor, the project combines advanced recycling technology with certified circular polymers to produce food-grade flexible packaging containing recycled content. 

Using recycled plastic

For food manufacturers, flexible packaging remains one of the more challenging formats to decarbonise due to strict food safety requirements and performance standards.

Chemical recycling is increasingly being explored as a complementary technology to mechanical recycling, particularly for mixed plastic waste streams that cannot be processed through conventional methods.

Unlike conventional mechanical recycling, which is often limited by contamination and material degradation, LYB's CirculenRevive polymers are produced through a chemical recycling process that converts mixed post-consumer plastic waste into feedstock for new polymer production.

The material is allocated using an ISCC PLUS-certified mass balance approach, allowing recycled feedstock to be incorporated into new plastic products while maintaining traceability throughout the manufacturing process.

This packaging solution is the result of a multi-stage production process spanning several manufacturing partners. LYB supplies the circular polymers, Taghleef Industries converts the material into a base film and Amcor transforms the film into the finished flexible packaging used by Mondelēz for its Marabou chocolate bars.

Central to LYB's long-term strategy is its MoReTec advanced recycling facility, currently under development to expand the company's chemical recycling capabilities.

Designed to process plastic waste that would otherwise be difficult to recycle, the facility is expected to produce around 50,000 tonnes of recycled feedstock annually once operational.

Manufacturing partnerships

Mondelēz is also working with Source One Plastics to source mixed plastic waste for conversion into feedstock, strengthening the supply of circular raw materials for future polymer production and helping scale recycled-content packaging across food manufacturing.

Richard Akkermans, Packaging Sustainability Manager at Mondelēz International, explains: “Looking ahead, our ambition is to increase the use of recycled plastic in our packaging materials, and we’re proud to collaborate with multiple value chain players, including LYB and other industry leaders, on this journey.

“This initiative shows what becomes possible when brand owners, recyclers, packaging material producers and converters work together to turn circular ambition into commercial reality.”

Currently, the Marabou packaging incorporates material attributed to 75% recycled content through the certified mass balance system.

Peter Vanacker, CEO of LYB, added that the MoReTec facility is expected to strengthen the company's ability to convert hard-to-recycle plastic waste into circular feedstocks that can be integrated into its existing production network.

The project also reflects wider changes across the packaging industry as manufacturers prepare for stricter recycled-content requirements under the European Union's Packaging and Packaging Waste Regulation (PPWR).

As demand grows for food-safe recycled materials, partnerships spanning recyclers, polymer producers, film manufacturers and packaging converters are becoming increasingly important in scaling circular manufacturing across the sector.