Why did Bonson choose Polypropylene for the RePlay Returnable Container System?

In the shift toward sustainable packaging solutions, material selection is one of the most critical decisions a company can make. Bonson believes that the ultimate environmental solution is a circular economy - one where the absolute LAST option for packaging disposal is landfill.

There is no one-size-fits-all solution in sustainable packaging. Our goal is to support customers in achieving their own sustainability commitments by giving them choices. This involves Bonson being totally transparent and making information that will help with decision making readily available. We are here to help guide you through what can often be a confusing world of acronyms, codes and greenwashing.

Bonson's belief guided the development of our RePlay returnable container system, designed to support the foodservice industry’s move toward reusable, more circular packaging models. After a rigorous evaluation of various materials, polypropylene (PP) emerged as the clear choice for our containers. 

Here's why.

Understanding the RePlay System

Bonson’s RePlay initiative is a practical step toward a reusable packaging model for food service operators, encouraging return, sanitisation, and reuse of containers - all while supporting New Zealand’s commitment to a circular economy for plastics. Moving away from hard-to-recycle and single-use plastics helps reduce plastic waste, improve our recycling systems and protect our environment. This shift is also part of a wider ambition to move Aotearoa New Zealand towards a low-emissions, low-waste economy.

In 2018, environment ministers endorsed the New Zealand Plastic Packaging Declaration, signed by New Zealand businesses, with the commitment for  100% of packaging to be reusable, recyclable, or compostable. 

RePlay helps organisations directly contribute to this goal by offering a packaging system designed for reuse and built from a material that’s both durable and widely recyclable.

Why Material Matters

The ideal material for reusable food containers must strike a delicate balance between:

• Safety
• Durability
• Functionality
• Environmental performance
• Regulatory compliance
• Appeal for both food service and its customers
• Cost

Bonson compared a range of materials including PET, glass, aluminium/steel, and plant-based alternatives with polypropylene. 

Let’s take a closer look at why PP stood out as the most viable, feasible and desirable option - and why some alternatives fell short.

The Benefits of Polypropylene

♻️ 1. Recyclability – Clear, Verified, and Widely Accepted

Polypropylene is one of the most widely recycled plastics in New Zealand, coded as #5. Around 95% of New Zealand households now have access to kerbside or drop-off recycling for polypropylene. Alternative compostable plastics or mixed materials can often confuse consumers and contaminate recycling streams.

Our approach complies with the WasteMINZ guidelines for recyclable claims, ensuring clarity and accuracy. These guidelines stress the importance of recyclability being practical, proven, and accepted - criteria that PP meets. For more technical insights into plastic codes, we recommend our guide: Understanding Codes on Plastics

✅ Claim: Recyclable in most regions of New Zealand, where facilities exist.

🔍 2. Clarity – A Clear Advantage in More Ways Than One

Polypropylene offers a high level of transparency, allowing food contents to remain visible to the customer. This improves food presentation, customer confidence, and portion visibility - especially important in takeaway and foodservice applications. It provides similar visibility to PET, but with far more functional advantages (more on that next).

🔒 3. Durability – Made to Last (Without Overpromising)

Bonson is careful about using the term "reusable", as per WasteMINZ New Zealand’s guidance. For a product to be marketed as reusable, it must withstand repeated cycles of its intended use, including washing and handling, without losing its functional integrity.

Polypropylene is the same material used in popular reusable brands like Sistema and Bonson’s own BonWare range, and also has a proven track record with recyclability. It is resistant to cracking, shattering, and warping, making it ideal for commercial and consumer-level reuse.

The number of potential reuse cycles is unknown. That's why, as part of our RePlay trials in supermarkets, Bonson is looking to understand and validate the number of cycles that polypropylene containers can be kept in use.

🛡️ 4. Food Safe – Trusted for Direct Contact

Bonson’s PP containers are manufactured to food-grade standards and are BPA and phthalate free, giving foodservice operators confidence in their safety. This is particularly important for hot-fill applications or items that require reheating or freezing.

Polypropylene is approved under FDA 21 CFR 177.1520 for food contact and is non-reactive, which reduces the risk of food contamination over multiple uses.

🔥 5. Heat-Proof – Microwavable and Fridge Safe

One of the key requirements for the RePlay container was versatility. The same container might go from the fridge, to the microwave, to the dishwasher - all in a single use cycle.

Polypropylene handles temperature fluctuations exceptionally well, making it safe for:

• Microwave reheating
• Dishwasher washing
• Refrigeration 

PET, while often clear and lightweight, is not microwave or dishwasher safe, which disqualifies it from true reuse applications in foodservice.

🧼 6. Dishwasher Safe – Built for Reuse in the Real World

A returnable container must withstand commercial and/or domestic dishwashing cycles to be viable in a reuse system. Polypropylene’s melting point of 130–170°C makes it durable enough for high-temperature cleaning, while maintaining structural integrity.

This was a non-negotiable feature for RePlay. Containers need to be reliably cleaned and sanitised - both for health compliance and consumer trust.

❄️ 7. Suitable for Refrigeration – No Warping or Degradation

Some plastics warp or crack in cold temperatures. Polypropylene performs well under refrigeration, keeping food protected and preserving structure. This is essential for both cold-chain logistics and consumer storage at home or work.

Why Not Other Materials?

We considered and evaluated other options, but each came with limitations that made them unsuitable for a returnable system like RePlay.

🚫 PET (Polyethylene Terephthalate)

PET is commonly used in cold beverage bottles and clear food containers. However, it’s:

• Not safe for microwaving
• Not suitable for dishwashing
• Prone to deformation under heat

While it is recyclable, its single-use nature doesn’t align with the functional needs of a returnable container system.

🚫 Glass

Glass has the benefit of being inert and reusable, but it has serious limitations:

• Heavy and breakable - a risk in commercial kitchens or delivery environments
• Safety hazard - broken glass can be dangerous
• High carbon footprint - energy-intensive to produce and transport

Due to its fragility and sanitation concerns, glass wasn’t a viable option.

🚫 Aluminium or Steel

Metal containers are durable but:

• Costly to manufacture and replace
• Can alter the taste of certain foods
• Require specialised cleaning to prevent corrosion or residue buildup

Additionally, they are not microwave-safe, further limiting their practicality in a foodservice setting.

🚫 Plant-Based Bioplastics

There’s growing interest in PLA (polylactic acid) and other compostable bioplastics. However:

• They are not microwave or dishwasher safe
• Require specific industrial composting facilities
• Often mistakenly placed in recycling, contaminating streams
• Don't perform well under repeated reuse

Polypropylene outperforms these materials in terms of durability, usability, and system compatibility.

More on this comparison here

Addressing Misconceptions and Greenwashing

The sustainability landscape is full of conflicting claims and buzzwords. "Biodegradable", "plant-based", and "green plastic" are often misused, leaving consumers confused.

At Bonson, we choose clarity over greenwashing. 

Polypropylene is:

• Genuinely recyclable in NZ (where systems exist)
• Proven in reuse systems
• Safe, functional, and efficient to produce
• Aligned with WasteMINZ's responsible claims framework

We are seeking to educate consumers and clients about the trade-offs and realities of each packaging type. Sustainability isn’t about optics - it’s about impact, practicality, and long-term performance.

Supporting Government Sustainability Goals

Bonson’s RePlay initiative is directly aligned with New Zealand’s plastics roadmap. In 2018, the Environment Ministers endorsed the goal that 100% of packaging in NZ should be reusable, recyclable or compostable by 2025.

By offering a durable, reusable, and recyclable container made from PP, we’re helping businesses:

• Reduce single-use waste
• Improve resource recovery
• Shift toward a circular economy
• Educate customers with accurate, compliant messaging

RePlay provides a bridge between today’s infrastructure and tomorrow’s goals - offering real solutions that work within the current system, while preparing for future advancements.

The Bigger Picture: Packaging Choices That Work

Bonson has never believed in “one solution fits all.” Our portfolio includes compostable options, recyclable PET, PP, and reusable formats because different applications call for different materials.

But when it comes to a returnable food container system that needs to be:

• Reusable (within regulated claims)
• Recyclable
• Safe
• Durable
• Practical

Polypropylene stands out as one of the most balanced, reliable, and proven materials available today.

Final Thoughts

Choosing polypropylene for the RePlay container system wasn’t about convenience - it was about responsibility. It’s the result of balancing performance, safety, environmental compliance, and real-world application in the food service environment.

We’re proud to offer packaging solutions that make reuse systems viable, accessible, and aligned with national goals - without compromising on quality or confusing consumers with greenwashed messaging.

Let’s move forward, together, with informed choices and a shift towards a circular economy for the materials we use.

📘 Learn more about Bonson’s RePlay system and our sustainability commitments:
👉 bonsonpackaging.co.nz/sustainability

📦 Read more about plastic codes and recycling in NZ:
👉 bonsonpackaging.co.nz/understand-codes-on-plastics