Collaboration Leads to Breakthrough

Emerald Packaging, Inc. won two Silver Awards—for Packaging Excellence and Technical Innovation—in the Flexible Packaging Association (FPA) Flexible Packaging Achievement Awards Competition for 2026. The entry that won the awards was the “30% Food-Contact Post-Consumer Recycled (PCR) Resin for 5 lbs. and 10 lbs. Potato Bags.”

The effort behind developing the package is an example of true collaboration across the value chain. Emerald Packaging led material development and supply chain coordination, working closely with Wada Farms as the grower-shipper partner and Idaho Package as a supply partner, with Walmart supporting commercialization and rollout. Michael Rincon, Emerald’s director of operations, developed the resin formula that drove film performance.

The development process included extensive resin qualification, food contact compliance verification, print and performance testing—especially for impact strength—and real-world trials beginning in fall 2024. 

Importantly, the final structure didn’t require equipment changes for packing operations, making adoption seamless.

Focus on the produce industry

Founded in 1963 and headquartered in Union City, California, Emerald Packaging is a U.S.-based flexible packaging manufacturer dedicated exclusively to the produce industry. 

As such, it is one of the largest suppliers of retail flexible packaging for fresh produce. 

Sustainability has been a core focus at Emerald for the last 15 years, driving innovations in recyclable and compostable structures, PCR content, and supply-chain efficiency, while ensuring performance and food safety remain uncompromised.

The “30% Food-Contact PCR Resin for 5 lbs. and 10 lbs. Potato Bags”was developed in direct response to retailer sustainability commitments, particularly Walmart’s Project Gigaton initiative, and increasing demand for scalable, compliant PCR solutions in produce packaging. 

The company’s goal was to create a bag that meaningfully reduces the use of virgin plastic while maintaining the durability, shelf appeal, and food-contact compliance required for high-volume retail distribution. This project demonstrated that PCR can move beyond pilot concepts and into everyday, on-shelf applications without disrupting operations.

This package is the first known 30% food-contact PCR bag introduced at scale in the retail potato category. The PCR polyethylene maintains both performance and food safety. To date, more than 1 million pounds of virgin polyethylene have been eliminated from the supply chain across several customers.

The resin used is supported by the U.S. Food and Drug Administration (FDA) for food-contact compliance through verified recycling processes and third-party certifications, ensuring safety, traceability, and regulatory confidence. The bag also features clear on-pack communication, making the sustainability benefits visible and easy for consumers to understand.

Finding markets

The primary go-to-market strategy is retail-led, beginning with national distribution through Walmart and expanding across additional produce verticals. 

Marketing efforts emphasize simple, transparent on-pack messaging that clearly calls out the 30% PCR content, paired with engagement focused on helping retailers and growers meet PCR and regulatory targets without operational disruption.

So far,the rollout has been highly successful. 

Since its launch, the 30% PCR structure has expanded to dozens of SKUs, with continued adoption underway. 

Retailer response has been especially positive, recognizing the solution as a practical way to meet sustainability benchmarks. Feedback from packing operations has also been strong, as the transition required no changes to existing equipment or processes.

As for the FPA contest,industry recognition provides valuable third-party validation for new materials innovation like food-contact PCR. A contest platform helps amplify awareness, reinforces credibility with retailers and brand partners, and accelerates broader adoption by demonstrating that this solution is proven, scalable, and commercially viable.

Scalability is a main feature

A key achievement of this project was not just reaching 30% PCR, but doing so with a reliable, repeatable supply chain capable of supporting national retail volumes. That scalability is what allows this innovation to move the needle industrywide.

This project shows what is possible when retailers, growers, and packaging manufacturers collaborate to reach a shared sustainability goal. 

The 30% food-contact PCR potato bag proves that environmentally responsible packaging need not come at the expense of performance, safety, or efficiency, and it sets a new benchmark for what’s achievable in produce packaging.

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Pallavi Joyappa is president of Emerald Packaging, Inc.

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Silver Award Winners Discuss Their Entries

Fourteen companies won Silver Awards in the 70th anniversary edition of the Flexible Packaging Achievement Awards Competition. The awards were presented during the 2026 Annual Meeting of the Flexible Packaging Association (FPA), held in Orlando, Florida, in March. Several Silver Award winners provided details about their entries by answering some written questions.

Glenroy, Inc.

FlexPack VOICE^®: Tell us how you came to develop the ByHeart Anywhere Pack, which won a Silver Award for Expanding the Use of Flexible Packaging.

Glenroy: The Anywhere Pack was developed as a collaboration between ByHeart and Glenroy®. ByHeart wanted an easy-open packaging option for on-the-go parents. As an emerging brand, they wanted to stand out on the shelf and offer something different to parents.

FPV: Talk a bit about how this expands the use of flexible packaging.

Glenroy: The ByHeart Anywhere Pack represents a meaningful shift from traditional infant formula packaging, with an on-the-go format designed for modern, mobile parents. Instead of the large rigid cans commonly used for powdered formulas, each Anywhere Pack contains 14 premeasured stick packets that are compact and travel-​ready—making it simple for busy parents to prepare a bottle anywhere. Described by customers as a “game changer,” the stick packs weigh less, take up less space, reduce spills and formula waste, eliminate measuring errors, and keep product fresh until use. ByHeart further invested in flexibles by packaging their stick packs in a stand-up pouch for maximum shelf impact.

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GOpak

FPV: Tell us how you came to develop the package for Regenie’s^® Pita Brittle, which won a Silver Award for Printing.

GOpak: We were fortunate to partner with Regenie’s founder on the development of this award-winning pouch. The main goal was to deliver her vision for the packaging with a domestic partner, while providing the versatility and speed of digital printing. This came together through collaboration between Regenie’s and our sales and graphics departments. We love this pouch because it shows what we can do from a printing and finishing standpoint. The silky soft-touch finish gives it that high-end feel, and the clean matte white base keeps everything looking crisp and intentional. On top of that, the metallic and spot gloss embellishments were used in all the right places. They catch the light and make the branding pop without feeling overdone. The color work is another big part of what makes this particular packaging stand out. This package grabs attention on the shelf, then reinforces that premium appeal the second it’s in your hands.

FPV: Anything that you want to add?

GOpak: With digital printing, we have a ton of flexibility, including the ability to experiment with color, finishes, and fine details on a single pouch. We can often match the look of other printing methods and, in many cases, elevate it with improved quality, plus options and embellishments that aren’t always possible on expedited timelines. This gives our partners more flexibility and speed to deliver in a demanding market.

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Polymerall Flexible Packaging

Begoña Herrero is the marketing specialist and sales coordinator with Polymerall Flexible Packaging.

FPV: Tell us about how you developed the Fazenda Blend Coffee Bag that won an International Silver Award for Technical Innovation.

Begoña Herrero: I originally met the Fazenda team at PACK EXPO International (Chicago) in 2024, where I connected closely with their operations team and began building a relationship around their packaging needs. After the show, we stayed in touch and found some common ground—including a shared passion for coffee—which helped strengthen the relationship. We later connected again at the Specialty Coffee Expo in Houston in 2025.

FPV: Talk a bit about the attributes that led to the technical innovation award.

Herrero: From a packaging standpoint, Fazenda wanted recyclability with a strong premium brand presence. Their coffee bags have a distinct look, using a mix of varnishes to achieve both shine and tactile appeal—something that really sets the packaging apart on a shelf while still aligning with sustainability goals. Fazenda wanted to break from typical-looking bags. Instead, they wanted to be different, with a taller, skinnier bag with a sharp, angular look. Recently, they also added a floral pattern with a matte finish to enhance their brand image. A very common situation is that nobody uses the bottom of the bags. Fazenda wanted to maximize the packaging real estate by implementing a QR code at the bottom.

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Printpack

Printpack won four honors: two Gold Awards and two Silver Awards. In response to questions, the company provided details about one of its products, the KIND^® Recyclable High Barrier Paper Bar Wrap, which won a Silver Award for Technical Innovation.

FPV: How was the package developed?

Printpack: KIND^®’s consumer base expects the brand to be “kind” not only to their bodies but also to the planet. That expectation encouraged it to reevaluate its iconic clear-window wrap and explore ways to move both the brand and the broader category toward more sustainable packaging. As KIND’s primary flexible packaging partner, Printpack collaborated with them to launch a test-and-learn pilot in select Whole Foods locations across the U.S. This effort was supported by Printpack’s recyclable paper platform, which has been in development for several years. KIND^® had previously conducted a smaller, online-only trial and felt ready to expand to a physical retail test to gather more robust consumer feedback.

FPV: Who was involved in the development?

Printpack: This project demonstrated the strength of the partnership between KIND® and Printpack. From the Printpack side, cross-functional teams—including product development, sustainability, manufacturing, operations, graphics, compliance, and commercial—played important roles throughout the process. Because paper behaves differently than traditional film on standard manufacturing equipment, several technical challenges required close collaboration and iterative problem-solving. Internal and external teams met frequently, often weekly, to keep the project aligned and on schedule.

FPV: Any other thoughts?

Printpack: One topic worth noting is the technical development required to make paper run efficiently in high-speed bar-wrapping applications. Achieving the right balance of barrier, seal integrity, machinability, and shelf appeal required significant engineering and cross-functional coordination.

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TC Transcontinental Packaging

FPV: Tell us how you came to develop the Cabot^® Creamery Vermont Seriously Sharp Cheddar Cheese 8 oz. package that won a Silver Award for Sustainability.

TC Transcontinental Packaging: This project started with Cabot’s desire to bring more sustainable packaging into the dairy aisle without compromising product protection. Dairy packaging has very specific performance requirements, such as moisture barrier, seal strength, and overall durability, and any change in materials must maintain those properties. So, our goal became: How do we meaningfully improve sustainability while keeping those critical functions intact? We partnered closely with Cabot and the Northeast Dairy Business Innovation Center to run real production trials using our new 30% post-consumer recycled (PCR) film structure. Those trials confirmed that the film held up beautifully, with no impact on product quality and no impact on line efficiency, which gave everyone the confidence to move forward.

FPV: Talk a bit more about the sustainability attributes.

TC: The key sustainability story here is the use of 30% PCR content in the film. That directly reduces the amount of virgin plastic used and improves the overall environmental footprint. The life-cycle analysis showed that switching to 30% PCR film meaningfully reduced environmental impact, with 23% less fossil fuel use, 15% lower greenhouse gas emissions, and 19% less water consumption compared to 100% virgin films. 

FPV: You also won a Printing Award for the HERSHEY’S KISSES^® Pokémon^® Collaboration. Some thoughts on the development of this package?

TC: This was a really fun, technically challenging project. We wrapped classic HERSHEY’S KISSES® in ultra-light 9-micron aluminum foil printed with 151 unique designs, one for every original Kanto region Pokémon. The surprise-and-delight moment was intentional, as the artwork sits on the bottom of each Hershey’s Kiss, so fans discover a new Pokémon as they unwrap it. On the technical side, printing vivid, high-coverage graphics on thin, reflective foil required extremely tight control of ink, impression, and registration. We ran 10 decks (eight colors plus primer and overprint varnish (OPV)) and used foil-specific compensation curves to maintain neutrals, spot colors, and fine details. Hershey also built a whole collectible ecosystem, including a Collector’s Case and a digital tracker, which meant color accuracy and design consistency were critical to fan engagement. To maintain operational efficiency, we stayed with Hershey’s standard foil and plume, so nothing changed in downstream manufacturing.

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Other Silver Award Winners