Sustainable Snacking: Aussie Trial Launches KitKat Bars in Recycled Packaging

A unique production run of the popular KitKat 4 Finger chocolate bars is now available in Australia, with the chocolate bars enclosed in wrappers made from locally recycled polypropylene (PP). This initiative is part of an experimental collaboration between Viva Energy and Nestlé, where soft plastic pyrolysis oil is transformed into food-grade recycled polypropylene.

Recycling Plastic into Edible Packaging

The experimental journey commenced in Victoria and extended across the entire production chain. Viva Energy processed over 9.5 tonnes of pyrolysis oil from plastics at its Geelong Refinery last year. This led to the creation of approximately 5 tonnes of recycled PP. The recycled PP was then used to fabricate seven million ISCC-certified KitKat wrappers in March, a joint venture involving Taghleef Industries and Amcor. The KitKat 4 Finger bars now on the market are encased in these environmentally friendly wrappers.

The pyrolysis oil derived from plastic was imported from Alterra in the United States for the trial, as Australia lacked the necessary materials at a commercial scale. To ensure the origin and journey of the recycled material were traceable, ISCC certification was implemented across the production chain.

The Geelong Refinery and the connected polymers plant, both owned by Viva Energy, are the only facilities in Australia with the capability to convert waste soft plastics into food-grade plastic feedstock chemically.

Creating a Circular Plastics Economy

Viva Energy’s executive GM energy and infrastructure, Bill Patterson, emphasized that the trial had proven that soft plastics pyrolysis oil could be used as a feedstock. This demonstrated the potential of adapting existing industrial infrastructure to support a circular plastics economy.

This trial project stemmed from a partnership formed in 2022 between Viva Energy and Nestlé, when the companies first used recycled soft plastic packaging for KitKat 4 Finger bars. Andrew Lawrey, Nestlé Oceania confectionery GM, expressed that the trial could provide valuable insights into the design of future packaging and commercial-scale recycling processes.

This ambitious plan’s successful implementation will rely on the domestic supply of feedstock, efficient collection and sorting systems, robust recycling infrastructure, and a comprehensive producer responsibility scheme.

Viva Energy and Cleanaway are currently conducting a feasibility study on a large-scale plastics recycling project. The Front-End Engineering and Design phase is anticipated to commence after the Australian Government finalizes the details regarding its packaging reforms.