The challenge
of mixed plastics
recycling
Luca Stramare – R&D Manager
COREPLA (Italy)
2
Plastic packaging
Protection
Convenience
Information
Producer
Transport
Consumer
Marketing
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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The problem begins at the end (of life)
Once the benefits of plastic packaging have been
exploited, then “blaming the packaging” begins…
Littering and “there is too much” packaging are
the most common examples
Plastic packaging is not responsible for littering.
Consumer behavior is
Companies have done great efforts to reduce
packaging weight and to remove unnecessary
packaging
The environmental impacts of plastic packaging
cannot be separated from the ones of the
product it contains, delivers and protects
Source: Wikipedia
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Tools to make plastic packaging more sustainable
Waste Prevention
Lightweighting
Waste Hierarchy
Reduce
Extended Producer
Responsibility Principle
Reuse
Recycle
Recycling Targets
Recover
Landfill
Separate
Collection
Design for
Recycling
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Extended Producer Responsibility in Italy
Plastic packaging waste
Recycling
targets
EPR rules
Recycling
targets
Italian Government
European Union
Direct management
of T&I plastic
packaging waste)
Plastic
packaging
separate
collection
Municipalities Citizens
Compensation
System funding
(packaging fee)
Industry
Plastic packaging
sorting and
preparation for
recycling
Industry owned Consortia
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Red: financial
Blue: materials
Yellow: area of COREPLA ownership
The CONAI-COREPLA system
Consumer
Manufacturer - Importer
of plastic packaging
Separate collection
Compensation
for collection
Packaging fee
Compensation
for sorting
Waste packaging sale
Converter
Recycling Company
Municipality
Energy
Recovery
Plant
Sorting Center
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Plastic packaging waste managed by COREPLA
Ton x 1000
900
800
700
2013
769 kt
12.9 kg/Person
Plastic Packaging Waste Collection
Raccolta
kg /Person
14
12
Kg/Person
Kg/Abitante
10
600
8
500
400
300
200
1998
110 kt
1.9 kg/Person
6
4
2
100
0
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Post-consumer plastic packaging recycling in Italy
38,6%
Ton x 1000
800
Plastic packaging
recycling rate Italy
700
600
500
400
300
EU Target: 22.5%
COREPLA
COREPLA
200
OtherOperatori
Operators
Altri
100
Total Italia
Totale
0
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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COREPLA - Plastic packaging recycling 2013
PET bottles
HDPE containers
Film
Polyolefins (PP and PE)
Other recycling
Ton x 1000
PET bottles
190.9
HDPE containers
62.8
Film
49.6
Polyolefins (PP and PE + PP mix)
85.3
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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The recycling chain is as strong as its weakest link
Municipalities
Citizens
Manufacturer
Importer
Sorting
Center
Recycling
Company
Converter
Plastic
Packaging
Separate collection
Packaging fee
(EPR)
Flakes - Pellets
Bales
Sorting by
Recycling
plastic type
Articles
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Sorting process
Clear
Sorting
Light blue
PET bottles
Mixed colors
HDPE containers
Large size film
Incoming
plastic
packaging
waste
Mixed polyolefins
Other plastics
Recycling (consolidated)
Recycling
(with some difficulties)
Energy recovery
Concrete
Steel mills
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Mixed polyolefins
Over time
Fluctuating composition
• Flexible/rigid packaging
According to local
consumption habits
• PE/PP ratio
• Other plastics residuals
Among sorting centers
Recycler
Recycled plastics
• Inconsistent quality
Applications
• Poor performance
• Limited (non demanding ones)
• Very low value
Converter • Low value articles
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Improved sorting process
Clear
Light blue
PET bottles
Mixed colors
HDPE containers
Large size film
Recycling
Rigid PP
Incoming
plastic
packaging
waste
Mixed polyolefins
Small size film
Other plastics
Sorting
PET trays, rigid PS, …
Remaining plastics
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Consolidated recycling – PET bottles
Most recycled plastic packaging material in Europe
• One out of two PET bottles in Europe is collected and recycled
• That means more than 1.6 Million tons
•
•
Established recycling value chain
Consolidated recycling outlets
• Textiles (relevant but declining)
• Strappings
• Other packaging (thermoforming)
• Bottle-to-bottle
• Chemical recycling (new)
• …
•
Bottle to bottle recycling
• Growth from zero to nearly 30% in ten years
• On average rPET content of European bottles: 10%
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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PET - Innovation without disruption
PET packaging industry
Innovations
• Barrier materials
• Scavengers
• Labels
• Glues
• Sleeves
• Closures
• Additives
• Colorants
• …
Increased
performance
and resource
efficiency
Shelf differentiation
The PET packaging industry has the right to innovate,
provided that innovations not distrupt the existing
PET recycling value chiain
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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The EPBP initiative
Protecting PET bottle-to-bottle recycling
Voluntary industry initiative
• European Federation of Bottled Waters (EFBW)
• European Association of Plastic Recycling and Recovery Organizations (EPRO)
Petcore Europe
• Plastics Recyclers Europe (PRE)
• European non-alcoholic beverages association (UNESDA)
PET bottle design guidelines for recycling
• Based on many years of experience
• Freely available on the website (www. petbottleplatform.eu)
Evaluation of PET bottle packaging solutions
• Expert panel covering whole value chain
• Strict business confidential information protection
• Opinions recognized by PET packaging end users
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Recycling: a powerful sustainability engine
Resources
Production
Product
Cycle
Recycling
Consumer
Waste
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Plastic packaging recycling sustainability
Environmental
Reduced waste generation
Environmental
Lower environmental impact
Energy saving
Local availability
Economical
New business opportunities
Cost savings
Environmentally friendly image
Social
Economical
Reduced dependence from imports
Innovation
Social
Job creation (collection, sorting recycling)
Knowledge development
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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10 years of sustainable plastic packaging
recycling in Italy
Environmental
7,1 Mio ton of CO2 emissions avoided
3,3 Mio ton of not landfilled waste
54 avoided landfills
Economical
318 Mio € of reduced disposal costs
668 Mio € of recycled plastics made available to industry, including SMEs
3000 Mio € of total plastic packaging business value
Recognition of Italy as worldwide provider of waste plastic packaging collection,
sorting, recycling and recycled plastics processing equipment and solutions
Social
About 8000 jobs generated in the value chain
Competences in collection, sorting, recycling and recycled plastics processing
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Conclusions
Plastic packaging recycling is challenged by
Different polymers and combinations of
Huge plastic packaging items variety
Italy turned the challenge into a circular economy opportunity
Sustainable plastic packaging waste recycling system
Current EU recycling targets exceeded by far
Recycled materials available to industry
Extensive knowledge in recycling and recycled plastics processing
Worldwide export of equipment and final products
Looking into the future: further opportunities
Increased recovery and recycling
New recycling processes
Further job creation
New business
2a Conferenza Nazionale sulla Chimica Sostenibile – Milano, 11 December 2014
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Thank You!