By Zach Muscato, Corporate Sustainability Manager at Plastic Ingenuity
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Post-consumer recycled (PCR) resins are an ideal solution to limit virgin plastic use, reduce environmental impact, and increase packaging circularity. But the PCR supply has flattened, and despite the economic law of supply and demand, market prices are historically low. It will take a multi-pronged approach to topple existing systemic barriers and revitalize the input stream.
PCR materials, including PET, PP, HDPE and some others, are commonly used in durable goods like T-shirt and carpet fibers, composite lumber, and retail packaging for products ranging from food and drinks to electronics.
PP (polypropylene) is a popular choice for packaging applications, yet the overall recycling rate for rigid PP containers remains low, at 8% in the U.S.1 An important factor impacting the recyclability of a packaging category is its acceptance rate in community recycling programs. The acceptance rate depends largely on packaging format. Although PP bottles, jugs and jars are accepted at a rate of 76%, formats like clamshells and trays have acceptance rates of 50%.2 A category must have an acceptance rate over 60% to be considered “widely recycled.”3
PET (polyethylene terephthalate) has a robust recycling infrastructure, making it one of the most recycled plastics globally. An impressive 89% of community recycling programs across the U.S. accept PET bottles, jugs and jars.2 Currently, PET thermoforms sit just below the “widely recycled” threshold at 54%, as do PET cups and lids (both 59%)2, so achieving that status is an attainable goal in the relatively short term.
The lower acceptance rate for PET thermoforms reflects structural obstacles. Contamination from look-alike materials, complex material properties and a lack of targeted processing technology can all make PET thermoform recycling more challenging. Similar systemic barriers contribute to PP recycling challenges, although the issues are different. For example, contamination of PP containers is typically caused by food residue. Additionally, many materials recovery facilities (MRFs) lack the advanced sorting technologies required to efficiently separate PP from other plastics in mixed recycling streams.
International brands, retailers and suppliers are committing to a more sustainable future by setting bold targets for decreasing their use of virgin plastics, shifting to reusable packaging, eliminating use of problematic plastics, designing packaging for recovery, increasing the use of PCR materials, and more. An example is the Ellen MacArthur Foundation’s Global Commitment, launched in . Signatories of the Global Commitment – including businesses representing 20% of all plastic produced globally and over 50 government entities – have undertaken the ambitious goal to make their packaging more recyclable, reusable or compostable, while also integrating higher amounts of recycled content.
The foundation’s most recent progress report acknowledges that while significant progress has been made around the world, more work is yet to be done to achieve a circular economy for plastic. Notably, Global Commitment signatories working toward robust goals have outperformed the market across nearly all target areas where comparable data exists, even if not all ambitions will be met by .4
Several factors are limiting PCR content incorporation into packaging at scale, including difficulty securing market premiums, competition from imported polymers, recycling variations between jurisdictions, and a lack of infrastructure investments. While solutions are currently being implemented, it will take collective action across the value chain to reinvigorate the PCR supply and secure a dedicated stream for packaging applications.
Despite increasing consumer demand for PCR and its growing usage in packaging across formats, prices have not risen accordingly. PCR material costs are tied to the cost of virgin plastics, meaning manufacturers can switch back and forth arbitrarily in some market-moving segments. Additionally, with prices uncommonly low, market forces are preventing reclaimers from capturing margins necessary for long-term economic sustainability.
Extended Producer Responsibility (EPR) policies are gaining momentum across the country, with five states currently implementing EPR for packaging laws and nearly a dozen more introducing EPR legislation. Under these mandates, producers are required to provide funding and/or services that assist in end-of-life management of covered products, including collection, sortation and processing. Well-designed EPR policies are essential to create favorable conditions for a plastic circular economy.
EPR and other policy measures can help incentivize or require design for plastic recovery, reuse and recycling; mobilize financing and investments in waste management infrastructure; and set standards and targets for the collection, sorting, reuse and recycling of packaging materials.
Alliance partnerships are also critical in these efforts, from sharing best practices for recyclability to stimulating demand for PCR to advocating for policy changes. Organizations include the Association of Plastics Recyclers (APR), the National Association for PET Container Resources (NAPCOR), the Sustainable Packaging Coalition, The Recycling Partnership, and many more.
With PCR material imports entering the U.S. market at increasing rates, it’s important to verify that the materials are indeed what they claim to be before using them in packaging. APR has developed a PCR certification program that includes requiring third-party verification to enhance credibility and reduce risk.5
Additionally, the U.S. Food and Drug Administration (FDA) ensures that recycled plastic used in food contact applications is safe for consumers. The FDA performs a thorough evaluation and issues favorable opinions through No Objection Letters (NOL) for food-grade recycled resins. The majority of the NOL’s currently listed in FDA’s searchable database are for food-grade recycled PET, and food-grade recycled PP is an emerging solution.6
Advanced recycling techniques and ISCC PLUS-certified materials also have the potential to unlock new opportunities for using PCR in more types of packaging.
A full-circle value chain for PCR materials continues to expand, including package manufacturers, retailers, recycling collectors, MRF operators, reclaimers, and PCR end users. PCR then can be repurposed into many types of new products, significantly reducing its environmental impact and contributing to a circular economy.
According to NAPCOR’s latest PET Recycling Report, the U.S. turned more than 286 million pounds of post-consumer recycled PET into new thermoforms in ,7 which were then used to protect and transport food and other important products to consumers. PET thermoforms had, on average, 16.9% PCR content in , up significantly from 10.8% in .7 This momentum with PET, PP and other resins must not only continue, but also accelerate and expand.
Circularity takes time, effort and investment. Now that the deadline for sustainability targets has arrived, we must do more to get the job done.
About the Author
Zach Muscato is the Corporate Sustainability Manager at Plastic Ingenuity and has dedicated his career to the thermoformed packaging industry. Learn more at https://www.plasticingenuity.com
1The Recycling Partnership, The State of Residential Recycling,
2The Recycling Partnership, Community Recycling Program Acceptance Data, Sept. 16,
3Federal Trade Commission Green Guides
4Ellen MacArthur Foundation, The Global Commitment, Nov. 18,
5Association of Plastic Recyclers, APR PCR Certification
6FDA, Searchable List of No Objection Letters
PCR, or Post-Consumer Recycled packaging, involves converting used materials into new packaging, offering a substantial reduction in carbon emissions and waste generation.
Why is PCR packaging so critical today? Because the world is facing the overwhelming challenge of ensuring the stability of our environment, and businesses worldwide are now being implored to uphold sustainable practices and reduce their environmental impact.
Statistics reveal a pressing need for eco-conscious solutions. As of , the global average consumption of plastic per person is 20.9 kg, and a worldwide total consumption of 158,943,925 tons per year. Enter PCR packaging: a promising avenue in the quest for sustainability.
Businesses and consumers alike stand to benefit significantly from PCR packaging. For companies, it presents an opportunity to align with eco-friendly initiatives, enhance brand reputation, and meet consumer demand for sustainable products. Consumers, on the other hand, gain access to custom packaging solutions in materials that minimize environmental harm and contribute to a circular economy.
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PCR packaging is made from post-consumer recycled materials, typically PCR plastics, such as polyethylene terephthalate (PET) and high-density polyethylene (HDPE). These are sourced from post-consumer waste, which undergoes a recycling process to create new packaging products.
What good is it that businesses start implementing this sustainable process?
PCR decreases plastic waste in landfills because of how much plastic it recycles. Because of recycling, it conserves natural resources and lowers carbon emissions associated with manufacturing virgin plastics. Lastly, the backbone of a self-sustaining industry is its ability to promote a circular economy.
Discover the intricate process behind PCR packaging, from post-consumer materials to eco-friendly packaging solutions. This process offers insight into how plastics, such as bottles, jars, and containers, are transformed into new packaging products.
PCR packaging’s journey starts with the meticulous collection of post-consumer materials, primarily focusing on HDPE and PCR plastic bottles. Some of these materials include, but are not limited to, the following:
These materials are sourced from diverse locations such as recycling bins, waste sorting facilities, and dedicated recycling centers. Since companies divert the delivery of these plastics from landfills to their factories, the collection process serves as a crucial step toward sustainable waste management practices.
Following collection, the post-consumer plastics undergo rigorous sorting and cleaning procedures. They’re sorted based on their type, color, and quality to ensure consistency in the recycling process.
Companies implement thorough cleaning methods to remove contaminants, such as labels, adhesives, and residues. The meticulous sorting and cleaning process is essential, guaranteeing the quality and purity of the recycled materials.
Once sorted and cleaned, the plastics enter various recycling technologies. These technologies mean both mechanical and chemical recycling methods.
Contact us to discuss your requirements of Post Consumer Recycled Resin. Our experienced sales team can help you identify the options that best suit your needs.
Mechanical recycling involves shredding the plastics into smaller pieces or pellets, which are then melted and extruded to form new packaging products.
Chemical recycling breaks down plastics into their constituent polymers by exposing them to different chemical agents to separate each layer of the plastic, allowing it to transform complex plastics into high-quality recycled materials suitable for PCR packaging applications.
The final stage of the PCR plastic’s journey involves the manufacturing of packaging products using recycled materials. The recycled polymer pellets obtained are then melted and molded into various packaging items such as bottles, containers, and packaging films.
Strict quality control measures are implemented throughout the manufacturing process to ensure that the PCR packaging products meet industry standards for strength, durability, and safety.
These packaging solutions contribute significantly to company sustainability efforts—reducing environmental impact and fostering a more eco-conscious approach across industries.
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Explore the diverse advantages that PCR packaging offers, from reducing carbon footprints and conserving resources to fostering corporate social responsibility and gaining a competitive edge in the market.
Precisely because of the decrease in energy consumption during production, you can expect a reduction in cost. You can also expect to see savings on various aspects of production, from raw material purchases to fuel consumption—contributing to overall profitability.
Adopting this packaging appeals to eco-conscious consumers, enhancing a brand’s market position and reputation. In the last five years, there has been a 71% increase in online searches for eco-friendly and sustainable businesses. By showcasing a commitment to sustainability, you attract customers who prioritize eco-friendly products, leading to increased sales and loyalty.
Moreover, promoting PCR in marketing campaigns strengthens your image as a sustainability leader, distinguishing it from competitors and capitalizing on the growing demand for environmentally responsible options.
PCR contributes to CSR by demonstrating a commitment to environmental sustainability. Companies that use this packaging showcase their dedication to reducing plastic waste and promoting eco-friendly practices.
Fortunately, even bigger companies are making an effort to keep their end of the bargain and show transparency. Research shows that around 80% of all Fortune 500 and S&P 500 companies now issue a CSR report. Adopting PCR packaging in your business can improve your CSR profiles, enhance public perception, and contribute positively to the environment and society.
Product Carbon Footprint (PCF) is pivotal in environmental sustainability as it measures a product’s greenhouse gas emissions. By knowing how much harmful gas they produce, companies can find ways to reduce their environmental impact. For example, a clothing brand can use PCF data to optimize transportation methods, such as switching to electric vehicles and lowering emissions and costs.
PCR packaging decreases the demand for petroleum-derived raw materials used in the production of virgin plastic. This conservation effort includes lessening energy consumption required for extraction, refining, and production processes involved in creating virgin plastics, appealing to eco-conscious consumers, and supporting environmentally friendly practices.
Overall, using recycled materials from post-consumer waste streams decreases the demand for virgin plastics derived from fossil fuels, thus lowering greenhouse gas emissions and conserving valuable natural resources. This sustainable approach encourages the reuse and recycling of materials, contributing to a circular economy where resources are kept in use for as long as possible—closing the loop on material usage.
As businesses increasingly prioritize sustainability, understanding the benefits and strategies of PCR packaging is crucial. Delve into sustainable packaging practices and regulatory trends worldwide, explore these informative resources: The Switch to Sustainable Packaging: A Guide for Your Business, Packaging Sustainability: Regulatory Trends Across the World
From cardboard boxes to PET bottles, discover how PCR materials are reshaping the packaging landscape for a greener future. Explore the different PCR packaging with these six versatile and sustainable solutions.
PET bottles are widely used for packaging beverages and other products due to their durability, cost-effectiveness, and recyclability. They are transparent, lightweight, and flexible, maintaining the quality and taste of the contents. Recycled PET bottles may have a slight difference in transparency compared to virgin PET but remain suitable for recycling.
Crafted from thick paper stock or heavy paper pulp, cardboard cartons are widely used for shipping and packaging products sold online or in retail stores. These industries heavily rely on cardboard cartons due to their durability, versatility, and cost-effectiveness in packaging and shipping a wide range of products.
HDPE packaging is a translucent, matte-finished plastic ideal for food and beverage containers, such as milk jugs and juice bottles, due to its lightweight, durable nature. HDPE’s chemical resistance, UV protection, and ability to maintain vibrant colors make it a versatile choice across industries.
This packaging is also used for personal care products, household cleaning items, toy manufacturing, and outdoor applications, such as recycling bins and pipes.
Glass packaging, composed of sand, soda ash, limestone, and recycled glass cullet, is a sustainable material that is endlessly reusable and recyclable. It is inert, ensuring food safety and health even after multiple recycling cycles.
Glass is advantageous as it’s tailored to the product type. For instance, PCR cosmetics packaging, along with food and beverages, pharmaceuticals, and perfumery, heavily relies on glass packaging for protection, transportation, branding, and waste prevention.
Aluminum, abundant in the earth’s crust, is extracted and used for its lightweight yet sturdy properties. Industries such as food, beverages, oil, chemicals, and other liquids utilize aluminum cans due to their freshness preservation, quick chilling ability, durability, recyclability, and efficient transportation advantages. They have one of the highest recycling rates and are favored for their convenience and environmental benefits.
Paperboard boxes are thick paper packaging materials commonly made from layers of compressed paper fibers. They offer endless possibilities for unique designs, including scoring, folding, embossing, hot foil stamping, UV coatings, and windowing. Food, beverage, cosmetics, pharmaceutical, and consumer goods industries often utilize paperboard packaging such as folding cartons for various packaging needs.
Want to elevate your packaging with cutting-edge printing techniques? Explore the in-depth guide comparing them: 5 Types of Packaging Printing Techniques: A Comparative Guide
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The world is constantly changing, and more brands are starting to adapt to improve their processes. Explore the latest innovations and sustainable strategies shaping the packaging industry today.
The current trend of adopting a circular economy approach in packaging is driven by the need to minimize waste and maximize resource efficiency. Rightfully so, as research indicates, witnessed a total of 158,943,925 tonnes of plastic waste, and 43% of this global plastic waste was projected to be mismanaged at the end of its lifecycle.
Companies must carefully monitor PCR sustainable packaging lifecycles to minimize environmental harm, including pollution, resource depletion, and ecosystem degradation. Companies can start redesigning their packaging to be easily recyclable and reusable, thus closing the loop on material usage and reducing environmental impact.
Businesses are increasingly focusing on designing packaging that is easy to recycle. Regulatory requirements and consumer demand for sustainable practices drive this trend. For instance, using mono-material packaging or eliminating complex material combinations makes recycling more efficient and cost-effective.
For example, Coca-Cola is rigorously pursuing the use of recycled materials in their packaging. Their goal is to make 100% of their packaging recyclable globally by and to use at least 50% recycled material in their packaging by .
The trend of innovating in material recycling involves developing new technologies and processes to recycle packaging materials effectively. For example, advancements in sorting technologies and chemical recycling methods are enabling the recycling of challenging materials, such as multi-layer plastics, contributing to a more circular economy.
Based on recent market research, the global Biodegradable Packaging Market is forecasted to grow at a CAGR of 6.2% from to , with a projected market size of USD 96.5 Billion in reaching USD 135.3 Billion by .
Concerns about plastic pollution and waste management are driving the shift towards biodegradable and compostable product packaging alternatives. Businesses are exploring options, such as bioplastics and compostable packaging materials, to offer environmentally friendly choices to consumers and meet sustainability goals.
There is a growing trend towards transparency in packaging, with businesses providing clear information about the recyclability and environmental impact of their products. A significant majority of consumers (80%) expressed greater trust in companies that offer transparent data supporting their sustainability initiatives, while 25% actively monitor government sustainability regulations to gauge their impact on preferred brands and products.
Consumer education initiatives, such as labeling schemes and sustainability certifications, help raise awareness and empower consumers to make eco-conscious purchasing decisions.
Take the next step towards sustainable packaging solutions. Learn more through this guide: Product Packaging for a Circular Economy: Everything You Need to Know
Employing sustainable packaging practices has revealed the immense potential of PCR packaging in reducing environmental impact across industries. From reducing carbon footprints to promoting circular economy practices, PCR packaging stands as a beacon of eco-conscious innovation that embraces a more holistic approach in the manufacturing industry.
For more information, please visit Recycled Plastic Products.