Recycled Plastics in Packaging Applications

62 Pages·4.669 MB·English

by  iSmithers Rapra Publishing

packaging > e-book
Recycled Plastics in
Packaging Applications
this e-book examines the current regulatory and
technology issues surrounding the use of recycled plastics
for packaging applications.
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Recycled Plastics in Packaging Applications
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table of contents
3 5
Executive Summary Recycled Plastics for Packaging Future Trends
introduction the Plastics Recycling option Recycled Plastics for Packaging and Food contact
the Packaging industry Recycled Plastics for Food Packaging energy costs—the Strongest Driver for Renewable Solutions
Recycled Plastics for Packaging Recycling Processes new Packaging materials--—Biopolymers
the Plastics Recycling option 4Plastic Process Scrap Recycling Future innovations and Processes
4Plastic Recycling methods, Approaches and Food 4mechanical Recycling 4other innovations
Packaging 4chemical or Feedstock Recycling
Regulatory landscape US ePA List of Tables and Figures
4US FDA Food notification (Fcn) System 4rPet container Recycling
4europe 4closed-loop Recycling
4Plastics implementing measure
outlook for Recycled Plastics 4 Regulatory Landscape
US FDA
1Introduction and Methodology 4current Regulations and initiatives
introduction 4Guidance for industry
objective 4US FDA Food notification (Fcn) System
Scope europe
methodology 4Pim
Definitions mercosur
2
The Packaging Industry
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packaging > e-book > recycled plastics in packaging applications
Executive Summary
the global Introduction was about $162 billion in 2010, which represents about 33% of
packaging industry Growth of recycled plastics for packaging applications is linked to the global packaging market value as shown in Figure 0.2 that
two key drivers: (1) the economics for cost-in-use compared to that follows.
in 2010 had an
of virgin plastic resin based on fossil-fuel feedstocks, and (2) the
estimated value of
supply chain for recycled plastic resin feedstocks (e.g., availability FIGURE 0.2 Global packaging demand by material, 2010
US$490 billion...
of municipal waste). the first driver, economics, is a bit of a wild
card. when the cost of fossil fuel-derived (from oil or gas) virgin there are a number of trends that will affect the growth of plastics
petroplastic resins increases, recycled plastics become that much consumed in packaging, many driven by the largest sector—food
CLICK TO VIEW
more attractive. it is the petroplastics that define the competitive packaging, including:
price point where recycled plastics can successfully compete. • Continued growth of plastics to the detriment of paper,
Furthermore, growth of recycled plastics specifically for food contact metal and glass
applications (largest end-use) is linked to a third key driver: the • Emphasis on “green” packaging and sustainability will
regulations that allow the safe use of recycled plastics in food drive plastics; specifically recycling, composting and use
packaging applications. of bioplastics
• Higher growth of flexible packaging versus rigid
The Packaging Industry packaging—downgauging and reduction in the amount
the global packaging industry in 2010 had an estimated value of of plastic used for the same container or pouch for
US$490 billion, as noted in Figure 0.1 below. this does not include reasons of better sustainability and lower freight costs
other packaging forms such as trash bags, plastic sheet, pallets, (less fuel for transport)
wood cartons or equipment. the two major designs for packaging • Growth in North America and Europe 3%-4% CAGR,
are flexible and rigid forms. Flexible—as the name implies—includes becoming more mature—plastics have made major
all designs made from film, foil, bag and pouch combinations. Rigid inroads into glass and metal packaging
includes all non-flexible design forms (primarily 3-D geometries), • Growth in China and other developing regions will
such as molded bottles, containers, cans and household items. continue to exceed 8% cAGR, especially for plastic
formats
CLICK TO VIEW FIGURE 0.1 Global rigid and flexible packaging demand, 2010 (%) • Demographic changes—smaller families, more
population working, older age and urbanization—all
Plastics are a very important material used across all packaging favor quick ready-serve type products and beverages,
designs. the global market for plastics in packaging applications which, in turn, will favor plastics in food packaging
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packaging > e-book > recycled plastics in packaging applications
Executive Summary
• P lastics provide a design medium for unique shapes However, no material is inert. when a material is put in contact
and consumer aesthetic appeal with foodstuffs, there is always a release of substances from the
• P lastics work well with new “smart packaging” formats material into the food. in the case of plastics, the very same plastic
• H owever, less barrier compared to glass or metal raises that is used as a barrier, container or closure also has the potential
issues of shelf-life and migration of plastic components to migrate into the food product, posing a potential health and
into food safety risk. Similar migration concerns also apply to the components
of plastics such as catalysts, monomers and additives.
the food packaging industry (including beverages) is a sub-sector
of overall packaging, and is by far the largest single segment, Because plastics represent about 40%-45% of all materials used in
representing about 58% (US$284 billion) of the total packaging food packaging, the issue of migration has become quite important
industry, as shown in Figure 0.3. the value of food packaging and one of the key areas for legislation and regulatory control,
that uses plastic is $107 billion, or about 22% of all packaging which will be discussed in later sections of this report.
and about 40% of food packaging. on a resin basis, this equals
approximately 60 million metric tons of plastic resins consumed contamination of food or beverages in a plastic container or bottle
and a primary source for recycled plastics, although less than half is of special concern to the recycling industry because recycled
this volume is actually recycled. plastic has had previous exposure to many contaminants and
environmental impacts. these include other plastics, solvents,
FIGURE 0.3 Global packaging demand by type, 2010 decayed food matter, adhesives, etc. Furthermore, the recycled
plastic has been exposed to multiple heat histories, which can cause
the food packaging industry is unique, because it is likely one plastic or additives to degrade/decompose into other substances.
of the few packaging sectors that has become a life-sustaining therefore, although a virgin plastic may have previously passed all
CLICK TO VIEW necessity for most global populations. it is the package that approvals for use, the same plastic material recycled must again
surrounds the food or beverage that protects the food content and prove its safety when used for food contact applications.
allows the customer to carry it and keep it fresh and safe. it is
the package materials, such as plastics or foil that create a barrier Recycled Plastics for Packaging
against the migration, diffusion and transmittance of bacteria, Recycling is a key approach for developing a more sustainable
oxygen, light, moisture and other potentially harmful external global polymer industry; it is also an important approach to
environment impacts. reducing the long-term cost of plastics use. with more than 95%
of all virgin plastics derived from nonrenewable fossil fuels such
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packaging > e-book > recycled plastics in packaging applications
Executive Summary
as crude oil and natural gas, plastics strongly affect the use and The Plastics Recycling Option
availability of such resources. compared to other options, plastics recycling is well positioned
to deliver high levels of value and high levels of energy capture
of potentially more importance is the ability to recapture (and (sustainability). in business terms, recycled plastics are good
reuse) the carbon atom contained in plastics, which was once part value for money when reused in packaging applications. when
of fossil fuels and contributes to the carbon cycle. Because the properly processed from refuse streams, they have almost the same
global use of polymers is so huge, polymer consumption has a large performance attributes as virgin plastics, often at half the cost.
impact on the use of nonrenewable fossil fuel-derived feedstocks,
which ultimately drives the need for polymer sustainability. Figure it’s well known to most global consumers and companies that plastic
0.4 shows the relevant share of polymers worldwide. packages are labeled with codes to identify the type of plastic used.
this enables consumers, collection agencies and recycling processors
FIGURE 0.4 Global share of polymer consumption by region, 2010 (%) to identify and separate those plastics that are recyclable.
Because fossil fuels are an ancient source of carbon, which has most plastics for recycling in the packaging industry are recovered
not participated in the present-day carbon cycle, releasing this from consumer refuse streams in the so-called municipal waste
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“extra” carbon into the atmosphere is believed to contribute to pool. this pool of materials is the most abundant source of recycled
global warming, as well as to the depletion of natural resources. materials for the packaging industry. in addition to plastics, this same
Recapturing this carbon is an essential part of environmental waste pool is a primary resource for other waste materials, including
sustainability and controlling the long-term costs of plastic metals, glass, paper and paperboard. each region of the world has a
materials. Recycling provides an economic pathway to polymer somewhat different approach toward recycling and the disposition of
sustainability because it shortcuts the carbon cycle, from carbon- their respective municipal waste pool as shown in table 0.1 below.
based feedstocks to polymers and then back to polymers again.
TABLE 0.1 Approaches to municipal waste by region (%)
other options to recycling plastics and/or preserving the carbon Country Recycling Composting Incineration Landfill
atom by controlling its final-use destination include: (1) incineration US 25 5 15 55
to energy, (2) composting for soil enrichment, and (3) landfill EU27 25 10 20 45
Japan 5 0 75 20
options, where methane gas can be captured for fuel. However,
India 5 5 5 85
this report focuses only on the recycled plastics option, which likely
Source: Pira International Ltd.
has the greatest economic and environmental benefit.
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packaging > e-book > recycled plastics in packaging applications
Executive Summary
it’s interesting to note that both the US and europe are more recycled plastics are available from the same source, city or region
closely aligned on municipal waste pool disposition, while Japan is of the world. the recycled plastic supply chain is only effective
strongly driven by incineration-to-energy approaches, and india is when laws are in place to promote active recycling by public
driven by landfill approaches. municipalities and when companies involved in recycling can create
an attractive value proposition for the collection and processing
examples of the most recycled products in the US are shown in of recycled plastic. it is clear from the above discussion that rigid
table 0.2. these higher levels of recycling plastic packaging are also plastics are easier to collect and recycle than flexible package
typical in much of the world. the reasons for higher recycling levels materials are. therefore, to increase the available supply of recycled
are simple: these products are large, single items and therefore plastics, it will be necessary to improve collection methods and
easy to separate and identify from the greater waste pool, and the processing methods for waste flexible packaging as well.
recycled plastic resin is readily used to produce other bottles and
containers, as well as fibers for textiles. Plastic Recycling Methods, Approaches and Food
Packaging Generally, the methods and approaches for recycling
TABLE 0.2 Recycled plastic products in the US (%) plastics is similar across packaging sectors, although recycled
Material Percent recycled (%) plastics for food packaging are under much greater government
Beverage bottles 50 regulatory scrutiny. Because food packaging is the largest source
Food containers 25
of recycled plastics and the most regulated sector to qualify for
Household containers 20
approved recycled plastic uses, the discussion on methods and
Other 5
approaches for recycling have been included together in this
Source: Pira International Ltd.
section.
indeed, plastics use in packaging is large, and the food and
beverage sector is the largest single market that contributes Safety is the guiding watchword for the use of recycled plastics in
recyclable plastics to municipal the waste streams. As previously food contact applications. For example, the largest use of recycled
described, plastics represent more than 20% of all global plastics for food contact applications is Pet (rPet) for beverage
packaging (60 million mt) and more than 40% of food packaging bottles and thermoformed food containers. Recycled resins like
materials (40 million mt, primarily due to rigid packaging use). rPet must comply with all general principles that apply to virgin
materials. the health and safety of the consumer is of prime
Perhaps the biggest issue facing plastic recycling in packaging importance when considering recycled plastics, or any materials in
is providing a consistent supply chain of required resins. not all food contact uses.
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