Many of the world’s leading brands have announced commitments to incorporate more post-consumer resin (PCR) in their packaging within the next 5-10 years. This sentiment is echoed by companies in a variety of industries around the world. Post-consumer resin is one solution to curbing the growing plastic pollution problem and decreasing the depletion of natural resources.
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To meet the rising demand for post-consumer resin, the return and recycling of specific types of used, empty plastic packaging by consumers is key. One of the ways Mauser Packaging Solutions addresses the increased need for post-consumer resin and supports the transformation from a linear to a circular packaging industry is through our integrated life cycle management program, which includes collection, reconditioning, recycling and manufacturing of products from PCR materials.
So, what is post-consumer resin, how is it made, and what are the benefits?
What is Post-Consumer Resin (PCR)?
According to the International Organization for Standardization’s (ISO) “Plastics Vocabulary” list, post-consumer or post-use material, is defined as “material generated by the end-users of products, that has fulfilled its intended purpose or can no longer be used (including material returned from within the distribution chain).” This differs from post-industrial, or pre-consumer material which is defined as “material diverted during a manufacturing process”.
Post-consumer resin (PCR) includes consumer packaging items such as plastic film, bottles, milk jugs, buckets, and also industrial packaging items such as IBC totes and poly drums. These items can be reprocessed into recycled plastic that’s used to make new products.
How is PCR manufactured at Mauser Packaging Solutions?
When an IBC or plastic drum reaches the end of its usable life and is no longer suitable for reconditioning, the first step in the recycling process is collection through the Mauser Packaging Solutions collection program. Empty containers and used plastic components are then sorted, shredded, ground, washed, dried and repelletized as high-quality post-consumer resin in compliance to ISO : standards. We call this in-house generated PCR “RecoleneTM.”
RecoleneTM, our premium recycled resin, is used to manufacture our own components and packaging, such as the Infinity Series of products. It offers the same benefits of reusability and recyclability as virgin resin and comparable technical performance. In alone, Mauser Packaging Solutions generated more than 51,000 metric tons of post-consumer resin from empty IBCs and plastic drums returned through our collection program.
What are the benefits using PCR?
Post-consumer resin offers a lower carbon footprint compared to virgin materials. Use of PCR diverts waste from landfills, decreases the consumption of virgin raw materials, and reduces emissions while promoting the circular economy.
How can your company contribute?
The action of recycling plastics is able to produce a substantial difference, and customers need to comprehend the favorable impact of recycling from the ecological and financial point of view. Consumers of plastic goods have the chance to create a gap, and companies and brand owners may direct the charge. By using a suitable plastic recycling strategy, companies can reduce toxic waste output and reduce waste management costs.
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At first, recycling plastic can have several other advantages apart from reducing the amount of plastic waste requiring disposal. This includes reduced consumption of energy, reduced amounts of solid waste going to landfills, conservation of non-renewable fossil fuels (plastic production uses 8% of the world's oil production), and reduced emissions of carbon dioxide (CO2), nitrogen oxide (NO) and sulfur dioxide (SO2) [1].
Post-consumer recycled (PCR) materials are materials extracted from waste separation, that is, materials from cities or companies that are subsequently separated in specific waste treatment facilities. The separation is usually done manually, as the different thermoplastics on the market may be similar in density or vary in their properties depending on the additives. Products produced from post-consumer recycled resin close the loop, directing used plastic away from landfills and toward recycling facilities [2].
1. Reduced Carbon Footprint
Choosing more sustainable packaging materials reduces waste and lowers carbon footprint by requiring fewer emissions than virgin plastics. As we strive for a more circular economy, the post-consumer recycled resin is the superior packaging material for future industries.
Greenhouse gases are an important reason behind the rising pollution levels in our surroundings. Because the entire process of plastics production requires burning oil, this generates a huge quantity of greenhouse gases. Recycling plastic rather than producing it from scratch consequently significantly reduces the emission of poisonous greenhouse gases. This means that less energy is used and natural resources are protected: the production process of virgin polymers requires natural resources such as water, oil, natural gas and coal as raw materials. Therefore, recycling polymer materials conserves valuable organic resources.
About 40% of the petroleum consumption from which conventional polymer materials are made can be easily reduced by recycling old and discarded plastic waste. Research has shown that post-consumer recycled resin has a much smaller carbon footprint than virgin plastics. The use of post-consumer recycled resin can also help solve one particularly important problem: microplastics in the environment. Microplastics derived from plastic waste dumped into the environment are small, artificial pieces of plastic with a diameter of 5 millimeters to 100 nanometers. These tiny pieces fill the oceans, seas and waterways, penetrating the organisms that live there. Microplastics have also been detected in the atmosphere, both in indoor and outdoor environments, as well as in our food chain [3, 4].
2. All the Benefits of Normal Plastic
Plastic is also used as a packaging material because of its superior performance. In comparison to other packaging alternatives, such as paper or cardboard, plastics offer a number of advantages, including:
increased durability and product protection;
stronger, rip-resistant packaging;
greater water and weather resistance [5].
3. Improved Customer Relations and Retention
Sometimes all you need is good marketing. With over 73% of consumers saying that they will make a consistent effort to choose more sustainable products, there's no better time than now to switch to more consumer-friendly plastics. These customers are also more likely to continue choosing your brand and products in the future if you have a more eco-friendly message, allowing you to not only gain new customers, but also to keep the ones you already have.
Research has shown that consumers will actually pay more for products made from post-consumer recycled resin. According to an international study conducted by Nielsen, 51% of respondents between the ages of 50 and 64, and 72% of respondents between the ages of 15 and 20 said they would pay more for products and services coming from companies that are dedicated to making a positive impact on the environment. In essence, a producer who invests in the post-consumer recycled resin can realize a return, especially if this investment is properly published [4].
4. Higher ROIs
While companies once took an economic hit by choosing post-consumer recycled resin over virgin polymers, times have changed. In fact, companies can now expect a far greater return on their investment by choosing recycled plastics instead of virgin ones. As the costs surrounding petroleum-based materials continue to rise, the cost of post-consumer recycled resin is projected to stay the same. So, while other companies have to deal with rising prices for plastic, you can keep your costs steady and protect your bottom line.
The fee for post-consumer recycled resin has been a bit greater than for virgin polymer. This can be because of the considerable washing, sorting, and processing necessary for recycled materials. However, as the total cost of petroleum-based raw materials is constantly increasing, we expect the cost of post-consumer plastics to remain the same. In addition, as more consumers recycle plastics, the law of supply and demand will make post-consumer plastics very attractive compared to virgin plastics [4].
5. Better Margins
Not only are people more likely to choose the sustainable option when picking from a sea of products, but you can also use greener packaging to help justify a higher price point. The majority of consumers are also willing to pay more for sustainable products over typical plastics, highlighting the potential for increased profits.
There are many benefits of using post-consumer recycled resin that matter to business, including:
better branding,
better customer relations in fulfilling consumer demands for sustainable products;
better margins with higher price points, again due to the demand;
long-term sustainability for economic growth [6].
6. Long-term Sustainability
In addition to the environmental sustainability of post-consumer recycled resin, you can also achieve long-term economic growth and sustainability by choosing recycled materials over virgin resins. PCR will continue to be the better packing option over non-recycled plastics, both economic and branding.
Post-consumer recycled resin is becoming increasingly important when it comes to choosing sustainable materials. In the face of imminent environmental threats, the plastics industry is gradually being transformed to take account of environmental and economic sustainability. The need to develop methodologies that can help achieve long-term sustainability, such as recycling and upcycling, is more crucial than ever. This requires thorough integration over the value chain [7].
7. Regulatory Compliance
Every state and local government has its own rules and regulations surrounding packaging and recycled products. By offering a more sustainable option, the post-consumer recycled resin is more regulatory-friendly, allowing you to easily meet any ecological requirements put on your business by the government.
As companies around the world strive to meet sustainable initiatives, demand for food contact-compliant recycled plastics is increasing. Government and regulatory agencies around the world are calling for an increase in the percentage of recycled materials used in products and packaging to reduce the amount of solid waste sent to landfills. Due to strict legislation, some industries may be affected. Manufacturers of packaging for food, medical and cosmetic products that use products containing post-consumer recycled resin must ensure the safety of their products for the health of consumers and must comply with packaging regulations worldwide [8].
Source:
[1] Use of recycled plastic in concrete: A review
[2] Life Cycle Assessment of a Plastic Part Injected with Recycled Polypropylene: A Comparison with Alternative Virgin Materials
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[3] Top 10 Benefits of Recycling Plastic
[4] The Benefits of Using Post-Consumer Plastics
[5] Top 7 Benefits of Post Consumer Recycled Resin
[6] Why should we focus on post-consumer recycled resins
[7] It’s Time to Use Post-Consumer Recycled Plastics in Products
[8] Recycled Plastics in Packaging: Safe Use and Regulatory Compliance
It’s clear that we have a trash problem. Americans produce 4.9 pounds of waste per person each day. That’s almost 300 million tons each year from one country alone!
Thankfully, many people and companies, are working hard to find ways to reduce the amount of wasted material in our world. Multiple global recycling initiatives have been started as a way to reuse material multiple times. Thanks to these initiatives, materials that would have been sent to landfills are able to be broken down and reused to make new products, like our 100% recycled hangtags.
Post-consumer recycled content (PCR) is the name for materials made from the everyday items that we recycle at home. The plastic milk jugs, old papers, and shipping boxes that are collected by municipal recycling programs are broken down into raw materials that are used to create new products. Many materials have the potential to be reused multiple times. In the US, about 75% of our waste could be recycled. Surprisingly though, not every item that is made from recycled materials contains post-consumer recycled content.
A strong domestic recycling system can make all the difference in creating a circular waste economy and increasing the amount of material that is able to be recycled. Here are a few benefits that a stronger recycling system would bring to the US:
Environmental protection – A better recycling system would reduce the amount of waste in our landfills, reduce the amount of natural resources needed to create products, and prevent pollution from the harvesting of natural resources.
Economic Gain – The system would create a currently untapped market for recycled materials and resources. It would also reduce energy costs needed for production.
Local Community Support – Additionally, this system would create jobs in communities across America in the recycling and manufacturing industries. It also reduces waste in local areas which has immense health benefits for residents.
Reduces greenhouse gas emissions. For every ton of paper recycled, 3.6 million tons of CO2 emissions are eliminated.
Reduces the number of trees needed for virgin fibers. Recycled paper uses recovered fibers from recycling instead of virgin fibers fresh from trees.
Requires less energy. Creating recycled paper requires less energy for processing.
It’s no surprise that consumers want to feel good about what they’re buying. Recent studies show that 61% of US consumers say that sustainability is an “important purchase criterion”. Using packaging that is made from post-consumer content and is easily recycled is an easy way to tap into this demand. Companies that are proactive with sustainable measures will stand out to eco-conscious consumers.
While post-consumer content is extremely eco-friendly, its fibers weaken over successive recycling cycles. This means that paper fibers cannot be recycled indefinitely. For example, an ordinary sheet of paper that you might find in your home office printer can only be recycled 5 to 7 times before the fibers become too short to hold the paper together.
To combat this, new, virgin paper fibers are often added to the pulp when creating recycled papers. This creates a blend of PCR and fresh materials that maintain a balance of sustainability and high-quality, usable paper. Recycled paper will be labeled with what percentage of the fiber is recycled versus new. For example, recycled paper that is labeled as 70% PCR will include 70% recycled fiber and 30% virgin fiber.
Post-consumer waste often contains contaminants, like stickers and adhesives, that make it more challenging to recycle than the purer pre-consumer content. So why focus on PCW?
Creating a market for PCW brings value to traditionally less desirable materials. Emphasizing the use of these materials will bring attention to how recycling actually works. Hopefully, this will lead to investments in all areas of the recycling process, including Materials Recovery Facilities (MRFs), manufacturers, and waste collection companies.
No matter if you’re a consumer or a producer, by supporting products made from recycled content, you’re directly contributing to a cleaner planet and a better future. Your printed materials and packaging are a reflection of your brand’s values, so finding the right supplier is extremely important.
In fact, among companies in those segments, nearly half say post consumer recycled resin is playing a significant role in their sustainable packaging strategies, according to Jabil’s recent study . Consumer packaged goods companies have a strong tendency (64%) to incorporate post consumer material and other recycled content as part of their product-level initiatives. Download the full survey report.
Ask many of the world's leading brands about their sustainable packaging plans and they will tell you: they aim to make their packaging 100% reusable or recyclable by . More specifically, many plan to source post-consumer recycled (PCR) materials—such as post consumer recycled resin—to get there. This sentiment is echoed across the entire landscape of food and beverage , as well as personal and home care segments.
While post consumer recycled resin seems to be the leading option to accomplish packaging sustainability in the industry, there are several considerations to make when sourcing PCR material:
There are four main plastics used in packaging: polyethylene (PE), polypropylene (PP), polystyrene (PS) and polyethylene terephthalate (PET). Currently, high density polyethylene (HDPE) and PET recycling are more common than others. The infrastructure is built to support the collection of these materials and many CPGs lead initiatives to educate consumers to recycle. PP is readily recyclable but needs more infrastructure and education around the material. Finally, PS is also recyclable as it is extremely tolerant to “re-melting,” but its collection presents difficulties due to its form factor.
Certain plastics are like oil and water—they don’t mix well. The contamination caused by their mixing, or worse yet, the addition of other factors (such as food, dirt, or other contaminants) can render the resins very difficult to reuse. The makeup of the post consumer resins can be a big obstacle in the industry’s endeavor to achieve a truly circular economy, which is a critical piece for packaging sustainability.
In addition, based on your company’s performance requirements of the product, the mixing of the materials can lead to further complications in achieving goals. Almost 60% of European plastics converting companies find it “hard” or “very hard” to reuse plastic scrap due to contamination, according to a European Plastics Converters Association study.
Then how can you ensure 100% purity for packaging materials?
The first step is to establish a set of recycled material goals for your product. Then, you need to partner with your supplier to evaluate and understand their sources and supply chain. They must have the appropriate quality controls and tests in place to ensure the material supplied meets your product’s specifications.
Therefore, it is imperative that you have full visibility into your supplier ecosystem and a strong understanding of how the post-consumer recycled plastic was sourced, processed and produced.
Not every type of recycled resin works for every use case or complies with applicable regulations.
In the United States, the FDA has guidelines for the use of recycled plastics in food packaging. Specifically, they have three concerns that:
Contaminants from the recycled material may end up in the food packaging
Non-regulated post-consumer materials may make their way into food packaging
Adjuvants in the recycled materials may not comply with food-contact regulations
Europe has more stringent guidelines. Under a regulation set over a decade ago, only “food-contact materials and articles that contain recycled plastic obtained from an authorized recycling process” may be used in the EU.
It is very likely that in the future more industry standards will be developed, and perhaps also government regulation, to ensure the material really is what it should be. Brands once again can partner with governments worldwide to help shape regulation and drive post consumer recycled content forward.
Over the long term, this area will become more like medicine or food—when we go to a grocery or drug store, we hardly ever think about whether the medicine or food is “good” or “safe.” We rely on the system in the background which ensures that it is.
Finding a steady source of high-quality post consumer recycled plastic is a difficult endeavor today. Consumers are not yet recycling enough plastic waste worldwide—which drastically impacts the supply. The reasons vary from geographically different regulations to the additional cost customers must occasionally incur to recycle. Furthermore, while many understand the importance of recycling, many are also confused on how to properly do it.
With such high demand for recycled materials, brands and packaging integrators must treat the sourcing of these resins as a partnership with their supplier, rather than a transactional exchange. Unlike sourcing virgin material, brands, converters and suppliers must work as a team and make the proper investments to build a viable infrastructure. Sometimes, that means launching community initiatives.
PepsiCo, for example, recognizes the importance of bringing all stakeholders together. To support the development of packaging sustainability, they launched PepsiCo Recycling, an initiative to improve plastics recycling infrastructure and raise awareness on the issue worldwide. With their partnerships through the program, they’ve provided recycling access to 33 million households across 700 communities in the U.S. since , collecting more than 115 million pounds of plastic bottle and recyclables.
These types of partnerships and investments can help you reach your sustainable packaging goals while making a big difference for the environment. Watch Jabil's documentary: The Sustainable Packaging Revolution for a better understanding of how integrators like Jabil, KW Plastics and Danimer Scientific are bringing innovative packaging solutions to the market.
While long-term partnerships and investments into the larger ecosystem will help to ensure a steady supply of post-consumer recycled resins, end-of-life must be addressed at the very beginning with product design. As it stands currently, approximately 30 percent of plastic packaging will never be reused or recycled without fundamental redesign or innovation, according to the World Economic Forum.
The current recycling infrastructure needs an overhaul, but brands can design their packages to optimize recyclability while working within the boundaries of the current infrastructure. This can be accomplished in different ways, such as making components out of a single polymer family, tethering a cap to a bottle or by minimizing how the packaging is assembled so it can be easily separated when necessary.
When designing product packaging, end-of-life must be top-of-mind. Otherwise, your company is contributing to the same problem it’s trying to overcome.