Jamestown Plastics has worked with a wide range of thermoformable materials for more than 67 years. In addition to virgin resins, our experience also includes recycled content options that can help reduce waste and stabilize long-term material programs. If you’ve read our overview of common thermoforming resins, this is the next step: understanding when recycled content makes sense, how it performs, and where it can deliver measurable ROI.
Recycled Plastic in Thermoforming
Recycled plastics used for thermoforming typically fall into two categories:
Post-industrial recycled content (PIR) comes from manufacturing scrap that is reclaimed and reprocessed. In many cases, PIR can be tightly controlled because the input stream is consistent and traceable.
Post-consumer recycled content (PCR) comes from products that have reached end-of-life and are collected, sorted, and reprocessed. When people reference PCR plastic, they’re usually talking about this stream. PCR programs can be highly effective, but they require the right supply and quality controls to maintain consistency.
One of the most common recycled materials used in thermoforming is recycled PET. Depending on the specification and format, you may also see it labeled as rPET or RPET. For packaging applications, RPET packaging benefits often include good stiffness, strong visual clarity, and compatibility with established recycling streams.
The right recycled option depends on what the formed part needs to do. Thin gauge packaging has different performance demands than heavy gauge dunnage or returnable trays. A good material strategy starts with the application, then works backward into the resin selection and sheet sourcing.
RPET in Packaging Programs
PET has long been a go-to material family for packaging because it balances strength, clarity, and processability. Recycled PET builds on those same fundamentals, which is why it’s frequently evaluated for packaging and tray programs where sustainability goals are tied to procurement requirements.
In many cases, the advantages are not limited to environmental reporting. RPET can support:
- Cost control when virgin resin pricing swings
- Stable performance for formed packaging, inserts, and trays
- Brand and retail alignment for programs that require recycled content
- Recyclability goals when packaging is designed for clean material streams
From a production standpoint, the goal is straightforward: choose a recycled sheet that behaves predictably during forming and trimming, then validate it against the real use environment. That’s where experience matters. Recycled content can be a smart choice, but it needs to be evaluated for thickness control, cosmetic requirements, and part geometry so the finished components perform the way the program expects.
PCR Plastic and Closed-Loop Manufacturing
PCR goals often start as a sustainability initiative, but the long-term value tends to show up in supply chain planning. Companies that rely heavily on virgin resin are exposed to price volatility, availability constraints, and shifting lead times. PCR content can reduce some of that exposure when it’s sourced through dependable channels.
For certain programs, the strongest approach is a closed-loop model. Closed-loop plastic manufacturing is a strategy where plastic is collected, reclaimed, and reused within a defined system. That system might be internal, or it might be structured with partners across the supply chain. In thermoforming, closed-loop programs often apply to reusable tray systems, returnable packaging, and other components that cycle through predictable workflows.
In the right application, a closed-loop program can:
- Divert plastic from landfill
- Reduce the need for virgin resin over time
- Improve material predictability from program to program
- Support customer sustainability reporting with real operational changes
Jamestown Plastics supports recycled material testing and program development as part of our sustainability approach. If you’re evaluating a recycled-content option, our Sustainability page is a good place to start for a high-level overview of how we approach materials, reusable designs, and recycling partnerships.
Cost Stability with Recycled Content
For many manufacturers, recycled content discussions become real when the numbers are clear. Sustainability may start the conversation, but purchasing teams usually want to know what it does to total program cost.
Virgin resin markets move quickly, and those swings create budgeting problems for long-term packaging programs. Recycled content can help smooth that volatility, especially when the supply stream is reliable and the sheet is engineered for consistent forming behavior. Some programs use recycled sheet as a direct substitute; others use a blended approach that balances recycled content with targeted performance requirements.
In practical terms, recycled plastic thermoforming materials can support ROI in a few ways:
Reducing exposure to virgin resin pricing. For packaging programs with recurring volumes, minimizing volatility matters. A recycled-content option can provide a more stable material strategy when pricing is unpredictable.
Improving overall waste reduction. When scrap and end-of-life materials are part of a structured recycling path, programs see less total waste across the lifecycle of the packaging system.
Supporting supply chain goals. Many companies now track sustainability metrics through procurement, supplier assessments, and reporting frameworks. Recycled-content materials can help meet those requirements without redesigning the entire package.
None of this works if the part performance suffers. Recycled content only delivers value when it forms cleanly, trims consistently, and holds up through handling, storage, and shipping. That’s why validation matters early, before a program scales.
Performance Considerations
Manufacturers evaluating recycled content usually ask the same questions first. It’s not skepticism; it’s normal risk management.
Will the part still meet strength requirements?
That depends on geometry, thickness, and material selection. Some recycled sheets perform extremely well in packaging applications. Others require adjustments to thickness or design features.
What about cosmetic expectations?
Clarity, haze, and surface appearance can vary based on the input stream and the sheet process. Packaging that needs high visibility often requires additional screening and testing.
Is the supply consistent enough for production?
A sustainable plastic program must work operationally. If lead times fluctuate or material quality shifts from batch to batch, the program absorbs that disruption. A well-managed sustainable plastic supply chain focuses on consistency as much as content.
Does it align with compliance and documentation needs?
Depending on the end market, material documentation and traceability may matter as much as the sheet itself. Jamestown Plastics operates with ISO 9001:2015 and ISO 13485:2016 (NY and TX) quality systems, and we can support documentation needs when they’re defined at the start of a project.
Recycled content isn’t a universal fit for every part or every industry. The goal is to evaluate it like any other material decision: performance first, then cost, then long-term stability.
Where Recycled Materials Make Sense
Recycled-content thermoforming materials are often a strong fit in applications where durability, repeatability, and program scale matter. Common examples include:
- Packaging trays and inserts for consumer and industrial products
- Blister and clamshell packaging where recycled content aligns with brand sustainability targets
- Returnable packaging and dunnage trays that support closed-loop workflows
- Handling trays and organizational packaging used in manufacturing environments
Some programs start with a single component and expand over time. Others evaluate recycled sheet during a full packaging redesign. Both approaches can work. What matters is having a clear view of the performance needs and the total lifecycle cost of the packaging system.
Performance And Sustainability Without Added Risk
Recycled content isn’t a trend that disappears after one reporting cycle. More manufacturers are building recycled materials into long-term packaging standards, which means the real differentiator is execution. The best programs treat recycled material adoption as an engineering decision supported by process control, supplier alignment, and upfront validation.
Jamestown Plastics helps manufacturers evaluate recycled content options through material testing, engineering support, and in-house tooling and manufacturing. If you’re exploring RPET, PCR, or other recycled sheet formats, our team can help you build a plan that balances cost, performance, and supply chain reliability.
Looking to integrate recycled content into your next packaging or thermoforming program? Connect with Jamestown Plastics to talk through material options and next steps.
