Recyclability by Design for Multilayer Plastic Flexible Packaging
A comparative study of recyclability by design guidelines and alignment among various stakeholders
Author
Summary, in English
Various recyclability by design (RBD) guidelines for multilayer plastic flexible packaging (MPFP) were assessed for consistency among parameter values. 9% consistency was observed, which is on the lower end of devised consistency scale. Poly-ethylene and poly-propylene are the two major emerging recycling streams in Danone Nutricia’s six key EU market countries. However, a need for consolidated centralized sorting and recycling data at EU level was identified as one of the major hinderance in designing and development of effective recyclable MPFP. Among the countries assessed for recycling efficiency, France was found to be the least MPFP recycling efficient country whereas The Netherlands is the most efficient. A lack of information exchange and collaboration among various stakeholders was also revealed, especially among brands and recyclers. At consumers end, a sense of responsibility towards plastic waste segregation was observed, however a lack of understanding about recyclable MPFP was also revealed through consumer survey. This factor been identified as a marketing opportunity. Majority stakeholders have a gravitation towards mono-material MPFP for recyclable design. This gives an insight into the future of MPFP, its design and recyclability in EU. However, barrier related issues are evident with mono-material MPFP that needs to be taken into consideration. A lack of consideration was observed among stakeholders regarding solvent based MPFP recycling technologies whose categories in mechanical recycling is still a gray area. Mono-material based MPFP is currently more cost intensive than conventional MPFP, hence a comparison in terms of cost, LCA as well as performance is a future study recommendation to assess the viability of both types.
Summary, in English
Multilayer plastic packaging is one of the most popular type of food packaging since 1960s when cellophane was renovated to use as food wrappers. It’s the kind that your potato chips, candies, baby milk powder and lentils are packed in. Packaging and food industry had not gravely thought of its waste management up un till recently. In 2018, China imposed a ban on plastic waste import from Europe and The USA, creating a paradigm shift in waste plastic management industry, brands and consumers perception. Around the same time, consumer awareness raised about marine pollution, creating huge pressure on brands to change their packaging policies. Ocean waste is still a challenge and plastic multilayer packaging from the UK are still found at shores of The Philippines and Indonesia.
Plastic recycling industry is non-uniform and highly based on the material type. So far glass, cardboard and plastic water bottle (made of poly-ethylene terephthalate or PET) recycling streams are more advanced than multilayers or other kinds of plastic. In fact, multilayer type of packaging is almost non-recyclable in Europe as of 2019.
My master thesis explored the reasons for non-recyclability of multilayer plastic packaging and one of the reason is lack of design guidelines. Recyclable by design is a popular approach for building an object such that it is recycled at end of life in an existing recycling infrastructure. Recyclability by design guidelines ensures this. An object is part of a ‘Circular Economy’ only if it is recycled in closed loop; this means the recycled material should be used to design the same object that it was once made of. Now, this is a challenging task, especially with plastics. Since, when plastics are recycled (using both mechanical and chemical recycling process) their molecules dis-integrate and loose structural quality. Hence, you can find water bottles with only a certain percentage of recycled content in them.
Multilayers are considered a contaminant in recycling stream due to different layers of plastic and metal bound together, which is not separable in a profitable business model. But, it can be made recyclable with advanced recyclable by design guideline that takes recycling infrastructure in consideration. Now, as mentioned earlier, the design guidelines for multilayers are low in number and at a nascent stage compared to other material design guidelines. In the study, a comparison was made among existing plastic multilayer packaging design guidelines with existing infrastructure in EU to understand the reasons of their infectiveness. Interviews with stakeholders like packaging developers, packaging suppliers and recyclers were conducted to understand their perspective about lack of recyclability of multilayers and future trends.
The study found that majority of the western European countries have fast developing poly-ethylene (PE) recycling stream and uniform recycling technologies. The comparison among existing design guidelines for multilayers revealed high inconsistency and lack of scientific evidence for their suggestions. Data collection and analysis also revealed lack of regulation, standardization of design and lack of communication as major reasons for ineffective recyclable design of plastic multilayers.
Based on the collected data, a new design guideline is recommended for plastic multilayer packaging based on PE recycling stream available in Europe. The suggested design guideline aims to prevent plastic multilayer from ending up in a landfill, incinerator or oceans. The guideline suggests using same material with different structural orientations for different layers. It also suggests eliminating metal or metallized layer that interferes with plastic waste sorting process in recycling centers. PE, though makes perfect sense to be used as a prominent material for future plastic multilayers, may not be able to provide the barrier properties as good as current conventional packaging. Hence, its use should be restricted to colder climates and low humidity countries of Northern Europe.
Plastic recycling industry is non-uniform and highly based on the material type. So far glass, cardboard and plastic water bottle (made of poly-ethylene terephthalate or PET) recycling streams are more advanced than multilayers or other kinds of plastic. In fact, multilayer type of packaging is almost non-recyclable in Europe as of 2019.
My master thesis explored the reasons for non-recyclability of multilayer plastic packaging and one of the reason is lack of design guidelines. Recyclable by design is a popular approach for building an object such that it is recycled at end of life in an existing recycling infrastructure. Recyclability by design guidelines ensures this. An object is part of a ‘Circular Economy’ only if it is recycled in closed loop; this means the recycled material should be used to design the same object that it was once made of. Now, this is a challenging task, especially with plastics. Since, when plastics are recycled (using both mechanical and chemical recycling process) their molecules dis-integrate and loose structural quality. Hence, you can find water bottles with only a certain percentage of recycled content in them.
Multilayers are considered a contaminant in recycling stream due to different layers of plastic and metal bound together, which is not separable in a profitable business model. But, it can be made recyclable with advanced recyclable by design guideline that takes recycling infrastructure in consideration. Now, as mentioned earlier, the design guidelines for multilayers are low in number and at a nascent stage compared to other material design guidelines. In the study, a comparison was made among existing plastic multilayer packaging design guidelines with existing infrastructure in EU to understand the reasons of their infectiveness. Interviews with stakeholders like packaging developers, packaging suppliers and recyclers were conducted to understand their perspective about lack of recyclability of multilayers and future trends.
The study found that majority of the western European countries have fast developing poly-ethylene (PE) recycling stream and uniform recycling technologies. The comparison among existing design guidelines for multilayers revealed high inconsistency and lack of scientific evidence for their suggestions. Data collection and analysis also revealed lack of regulation, standardization of design and lack of communication as major reasons for ineffective recyclable design of plastic multilayers.
Based on the collected data, a new design guideline is recommended for plastic multilayer packaging based on PE recycling stream available in Europe. The suggested design guideline aims to prevent plastic multilayer from ending up in a landfill, incinerator or oceans. The guideline suggests using same material with different structural orientations for different layers. It also suggests eliminating metal or metallized layer that interferes with plastic waste sorting process in recycling centers. PE, though makes perfect sense to be used as a prominent material for future plastic multilayers, may not be able to provide the barrier properties as good as current conventional packaging. Hence, its use should be restricted to colder climates and low humidity countries of Northern Europe.
Department/s
Publishing year
2020
Language
English
Full text
Document type
Student publication for Master's degree (two years)
Topic
- Technology and Engineering
Keywords
- Recyclability by design
- multilayer flexible packaging
- PE
- PP
- plastic recycling
- circular plastic economy
Supervisor
- Katrin Molina-Besch (Doktorand)