Viva Energy has produced its first ISCC+ certified bio-based polymer from used cooking oil (UCO), at its Geelong Refinery, an innovation that sets the stage for producing food-grade recycled plastic packaging in Australia.
The development follows a proof-of-concept trial in which Viva Energy processed a batch of UCO through its catalytic cracker and adjacent polypropylene plant in Geelong, Victoria. The UCO was sourced from snack manufacturer Intersnack ANZ in New South Wales, where it had been used in the production of popular snack brands such as Kettle Chips, CC’s, Natural Chip Company, Thins, and Cheezels. Later this year, Intersnack ANZ plans to use the resulting ISCC+ certified bio-based material to manufacture plastic packaging for some of its snack products.
The initiative complements Viva Energy’s ongoing plastic recycling project with Cleanaway. As part of the trial, Cleanaway collected and processed the UCO to remove impurities before delivering it to the Geelong Refinery. To facilitate the transition to alternative feedstocks, Viva Energy has also invested in infrastructure upgrades at the refinery.
Viva Energy chief strategy officer Lachlan Pfeiffer described the project as a pivotal development in sustainable packaging solutions. “Over time, the plan is to expand the scale of processing, create new roles at the refinery, and transform the site into a broader energy hub,” he said. “There is growing interest in plastic with recycled content and in more sustainable solutions to Australia’s plastic waste challenges, particularly from food manufacturers like Intersnack ANZ. We believe there will be a strong market for food-grade packaging made from recycled materials, but we recognise there is a need for regulatory support for this to be a success.”
The initiative complements Viva Energy’s ongoing plastic recycling project with Cleanaway. As part of the trial, Cleanaway collected and processed the UCO to remove impurities before delivering it to the Geelong Refinery. To facilitate the transition to alternative feedstocks, Viva Energy has also invested in infrastructure upgrades at the refinery.
For Intersnack ANZ, the initiative represents a major step towards reducing its environmental footprint and scope 3 carbon emissions. Intersnack ANZ CEO Kurt Preshaw said, “We are excited about this important first step for Intersnack ANZ and its potential to address the broader industry challenge of plastic waste. Piloting used cooking oil as a feedstock has provided Viva Energy with an effective way to explore alternative inputs for the refinery, opening a pathway for the acceptance of oil from Australian recycled soft plastics.”
The project aligns with the increasing consumer and regulatory push for sustainable packaging solutions. “Our customers and consumers expect us to reduce our reliance on virgin plastic, and this initiative is a critical first step toward that goal,” Preshaw added. “As the project progresses, we look forward to measuring its impact on emissions and continuing our collaboration to achieve our ambitious sustainability targets.”
Viva Energy plans to expand its scope in alternative feedstocks, with trials of plastic pyrolysis oil and tyre pyrolysis oil expected in the coming months. “These initiatives demonstrate our ability to play a critical role in establishing a more sustainable economy in Australia,” Pfeiffer said. “Over the next 12 months, we will quantify the environmental benefits of the bio, recycled, and lower-carbon fuels and products we produce.”
The company’s process is certified through International Sustainability and Carbon Certification (ISCC+), ensuring transparency in the renewable feedstock content of its recycled plastic. Under the mass balance free attribution model, the sustainable materials are tracked through processing and allocated to the final product, even if mixed with traditional hydrocarbons.
This latest initiative positions Viva Energy as a key player in the shift towards sustainable packaging and reinforces the role of Australian industry in developing localised solutions for hard-to-recycle plastic waste.
