Paper Pots- Background

As part of our parent company Unilever’s commitment to reduce our use of virgin plastic we’re looking at ways to innovate our packaging to use less, better and no plastic – including switching to alternative packaging materials, like paper. Our Pot Noodle paper pot is the biggest innovation to the brand’s iconic pot since it first launched over 40 years ago!

Our paper pots have been designed to significantly reduce the virgin plastic used in each pot whilst ensuring the packaging still holds its distinctive shape and delivers the same quality Pot Noodle eating experience.

The 2024 trial of paper pots was a success, allowing us to install and trial new machinery to run paper through the production lines at our Pot Noodle factory.

Following the success of this trial, we announced plans to switch half of the Pot Noodle range* – moving the majority of our most popular flavours, Original Curry, Beef & Tomato and Chicken & Mushroom, in both Standard and King Size - to paper pots by the end of 2026.

The switch will start with the majority of standard Pot Noodle Curry, Beef and Chicken pots moving to paper in 2025, followed by the majority of the same flavours in the King Size switching to paper by the end of 2026*. Once the 50% move has been complete, approximately 98 million Pot Noodle pots a year will be made with certified sustainably sourced paper** rather than plastic.

We have calculated*** that the switch to paper pots, once complete, will save around 1,870 tonnes of virgin plastic whilst reducing the total life cycle carbon footprint of the product by 14% meaning an approximate total reduction of 3,800**** tonnes carbon dioxide equivalents (tCO2-eq.) per year.

*The majority (80%) of Pot Noodle’s biggest flavours across their standard and king size ranges, Chicken, Beef and Curry, will be moving to paper pots. Around 80% of  standard size Chicken, Beef and Curry Pot Noodle will move to paper in 2025. Followed by around 80% of King Size Chicken, Beef and Curry Pot Noodles switching to paper by the end of 2026 

**Unilever sources responsibly sourced paper from FSC and PEFC

***Based on a life cycle assessment (LCA) study carried out on a Pot Noodle Chicken & mushroom Standard Pot by a third party to ISO 14040/44 including an independent peer review. Impact for other flavour products is assumed to be the similar because the pot used for all flavours is the same and recipe differences have an insignificant impact on the LCA result

****Based on LCA for Pot Noodle Chicken & mushroom Standard Pot, reduction is 0.039kg CO2-eq per pot x 98million (50% of the Pot Noodle range is 98million pots)

Why are we making this change?

Innovating with alternative materials – like paper – is a key part of Unilever's sustainable packaging strategy and will play an important role in reducing our use of virgin plastic, alongside increasing our use of recycled content, moving to ultra-concentrated formulas which use smaller bottles, and other packaging innovations such as refillable bottles. 

Following a full product life cycle assessment (LCA), we know that by moving from plastic to paper pots, as well as a significant virgin plastic reduction, reduces the Co2 footprint of the total lifecycle of each pot by 14% which is 3,800 tonnes carbon dioxide equivalents (tCO2-eq.) per year.

Why are we moving 50% of our range?

Moving 50% of our Pot Noodle range is a significant shift. Switching over 98 million pots to paper and saving 1,870 tonnes of plastic every year as is a big step in reducing virgin plastic whilst helping shoppers to make a more sustainable everyday choice.

Moving half of the range to paper pots will allow us to invest in the changes needed at our factory to run paper through some of our production lines, which requires a significant adaption to machinery and engineering, whilst also continuing to invest in the growth and other capabilities at our noodle factory, alongside new innovations and launches for our Pot Noodle shoppers. 

Is the paper pot recyclable?

The pots are made from 90% paper as a single layer of ultra-thin plastic film is used to provide barrier protection inside the pot, which ensures ingredients remain fresh – helping to extend the shelf life of Pot Noodle’s and reduce food waste – whilst also protecting the structure of the pot when water is added, without inhibiting the recyclability of the pot.

The new pots can be recycled at home through kerbside recycling collection with other cardboard and paper packaging and include OPRL’s 'Recycle with Paper’ label on-pack to provide clear guidance to shoppers on how to dispose of their Pot Noodle pot.

To ensure the paper pots can be recycled in the UK, two important tests have been carried out – a sorting test and a pulping test.  

The sorting test confirmed that the paper pots are correctly sorted at waste management facilities and channelled into the paper and cardboard workstream. This testing and certificate confirm that the pots can be recycled with available sorting and recycling technologies commonly used at industrial scale in the recycling sector in the UK* 

A pulping test demonstrated that the paper pot can then be recycled in a standard paper mill and turned into recycled paper than can be reused.**

* The pots were assessed for recyclability by Circpack® following the CERTIFY methodology. Based on the results a Ready to recycle Class C certification was awarded. 

** The pots were tested according to the CEPI recyclability laboratory test method, part 1, version 2 and passed as recyclable with the score 60/100.