Polyolefins, such as polyethylene (PE) and polypropylene (PP), are widely utilized in injection-molded packaging due to their favorable properties. These thermoplastics offer advantages like low cost, chemical resistance, durability, and ease of processing, making them suitable for various applications, including rigid containers, threads, and closures. Despite their widespread use, most polyolefins are derived from petrochemicals and are resistant to biodegradation, leading to long-term persistence in the environment and growing concerns around plastic waste and pollution. 

Various biodegradable and compostable materials, such as polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polyhydroxyalkanoates (PHA), and thermoplastic starch (TPS) blends, have been explored as alternatives to traditional polyolefins. However, many of these materials lack the mechanical strength or processability required for injection molding applications. Moreover, some have densities greater than 1 g/cm³, which causes them to sink in water and hinders separation in recycling systems that rely on flotation to isolate polyolefins. This density mismatch is particularly problematic in fiber-based packaging formats, where plastic closures must float during paper repulping for efficient separation from the fiber stream, and in some cases, must also be compatible with PET bottle recycling processes. 

Developing a resin with a density below 1 g/cm³ that can be formed into injection-molded closures and other primary packaging components would address both the mechanical and recycling-level requirements for fiber-based packaging combinations. Such a material would support PepsiCo’s sustainability goals by reducing reliance on fossil-based plastics, minimizing environmental impact, meeting corporate targets, complying with regulations, and addressing consumer demand for eco-friendly packaging.