PROCESSORS WEIGH IN ON MATERIALS
PROCESSORS WEIGH IN ON MATERIALS
In addressing material selection for sustainability, processors say one of the biggest trends is toward more post-consumer recycled (PCR) content. Says TricorBraun’s Darsey, “With the advent of FDA-approved recycled HDPE and cleaner recycling streams, we have seen more companies not only allowing but also feeling safer moving in the direction of higher and higher PCR content. We have a number of customers running 100% PCR for personal-care products—something unheard of just a few years back. ”
According to Dordan’s Slavin, a lot of plastic mold manufcturer packages have been converted from PVC to RPET, and more thermoformed containers appear to be moving into PET from PP and PS because PET is the most-recycled resin in North america.
Most of Amcor’s products are PET and some are HDPE. Clark notes that while certain markets do seek 100% recycled content, most clients—representing the vast majority of the millions of pounds of PCR going into major commercial products—seek recycle content in the 10% to 25% range. Why this low? Because good PCR supply is tough to come by, and PCR-containing bottles aren’t as aesthetically pleasing as their virgin counterparts. “For plastics packaging, increasing the recyclability efforts in our country requires a bigger effort be undertaken, ” Clark says. “There have not been enough incentives for private recycling companies or municipalities. But we are seeing industry now looking for ways to partner with local and state governments, and groups such as the SPC have been formed to support this. ”
“Sustainability is becoming a part of everyday life, and making sure our cups can be recycled as part of that ongoing activity is a priority, ” says Kim Frankovich, vp of sustainability for Solo Cup Co., Highland Park, Ill., (solocup.com). Solo has been proactive since 2008, when it launched the Bare by Solo brand, the first full line of “eco-forward,” single-use foodservice products using recycled, recyclable, compostable, or renewable materials.
In 2011, the basket mould company launched the Solo Cup Brigade, a cup-recycling program created with recycler TerraCycle, Trenton, N. J., for individuals, charities and others to collect Solo Squared plastic PS cups and return them to TerraCycle for recycling. For every Solo cup returned, 2￠ will be donated to keep America Beautiful or to a non-profit or school chosen by the Brigade member. The recycled cup material will be used to make equipment for playgrounds, park benches, and outdoor furniture.
Biobased resins are also being considered, but many preform mould processors believe these materials are still in the embryonic stage. Says TricorBraun’s Darsey, “The move to biobased resins will be slower, as capacity is slow to come on line for things like biobased HDPE, PET, and soon biobased PP. Only the highest-profile projects will have material available over the next few years. ”
Clark says Amcor is looking primarily at biobased PET and PP from Braskem of Brazil (braskem.com, U.S. office in Houston). “We are leaning toward biobased PET versus other biopolymers, as we feel it’s important to preserve our existing recycling systems, and these newer biobased materials are very compatible and a drop-in for the current recycling stream,” he says, adding they are also more expensive.
Dordan offers alternative-material consulting through its Bio Resin Show N Tell program, the result of two-year internal R&D research on the performance and environmental profiles of biobased, compostable, and biodegradable resins. Materials sampled to date include PLA, PLA plus starch, cellulose acetate, PHA, biobased PET, and foamed RPET. Thermoformed samples are presented to customers alongside comparative specs and pricing, with special attention to end-of-life requirements. “There is a cost premium associated with most of the non-traditional resins included in our BioResin Show N Tell; this is why we have yet to run a full production order in any of these resins, ” says Slavin.
In addressing material selection for sustainability, processors say one of the biggest trends is toward more post-consumer recycled (PCR) content. Says TricorBraun’s Darsey, “With the advent of FDA-approved recycled HDPE and cleaner recycling streams, we have seen more companies not only allowing but also feeling safer moving in the direction of higher and higher PCR content. We have a number of customers running 100% PCR for personal-care products—something unheard of just a few years back. ”
According to Dordan’s Slavin, a lot of plastic mold manufcturer packages have been converted from PVC to RPET, and more thermoformed containers appear to be moving into PET from PP and PS because PET is the most-recycled resin in North america.
Most of Amcor’s products are PET and some are HDPE. Clark notes that while certain markets do seek 100% recycled content, most clients—representing the vast majority of the millions of pounds of PCR going into major commercial products—seek recycle content in the 10% to 25% range. Why this low? Because good PCR supply is tough to come by, and PCR-containing bottles aren’t as aesthetically pleasing as their virgin counterparts. “For plastics packaging, increasing the recyclability efforts in our country requires a bigger effort be undertaken, ” Clark says. “There have not been enough incentives for private recycling companies or municipalities. But we are seeing industry now looking for ways to partner with local and state governments, and groups such as the SPC have been formed to support this. ”
“Sustainability is becoming a part of everyday life, and making sure our cups can be recycled as part of that ongoing activity is a priority, ” says Kim Frankovich, vp of sustainability for Solo Cup Co., Highland Park, Ill., (solocup.com). Solo has been proactive since 2008, when it launched the Bare by Solo brand, the first full line of “eco-forward,” single-use foodservice products using recycled, recyclable, compostable, or renewable materials.
In 2011, the basket mould company launched the Solo Cup Brigade, a cup-recycling program created with recycler TerraCycle, Trenton, N. J., for individuals, charities and others to collect Solo Squared plastic PS cups and return them to TerraCycle for recycling. For every Solo cup returned, 2￠ will be donated to keep America Beautiful or to a non-profit or school chosen by the Brigade member. The recycled cup material will be used to make equipment for playgrounds, park benches, and outdoor furniture.
Biobased resins are also being considered, but many preform mould processors believe these materials are still in the embryonic stage. Says TricorBraun’s Darsey, “The move to biobased resins will be slower, as capacity is slow to come on line for things like biobased HDPE, PET, and soon biobased PP. Only the highest-profile projects will have material available over the next few years. ”
Clark says Amcor is looking primarily at biobased PET and PP from Braskem of Brazil (braskem.com, U.S. office in Houston). “We are leaning toward biobased PET versus other biopolymers, as we feel it’s important to preserve our existing recycling systems, and these newer biobased materials are very compatible and a drop-in for the current recycling stream,” he says, adding they are also more expensive.
Dordan offers alternative-material consulting through its Bio Resin Show N Tell program, the result of two-year internal R&D research on the performance and environmental profiles of biobased, compostable, and biodegradable resins. Materials sampled to date include PLA, PLA plus starch, cellulose acetate, PHA, biobased PET, and foamed RPET. Thermoformed samples are presented to customers alongside comparative specs and pricing, with special attention to end-of-life requirements. “There is a cost premium associated with most of the non-traditional resins included in our BioResin Show N Tell; this is why we have yet to run a full production order in any of these resins, ” says Slavin.
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