Top 10 Packaging Challenges For Recycling in a MRF REVISITED. 8 th Canadian Waste Resource Symposium April 28th, 2016

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1 Top 10 Packaging Challenges For Recycling in a MRF REVISITED 8 th Canadian Waste Resource Symposium April 28th, 2016

2 The Way VISION A World Without Packaging Waste GOAL To minimize system recovery costs while maximizing recycling rates and the value of recovered materials

3 Finding Balance Optimizing for the Packaging Value Chain Negative environmental impact Optimum Pack Design Minimum environmental impact Underpackaging Overpackaging Minimum material Increasing packaging material use Diagram courtesy of Innventia AB

4 Finding Balance Product Design & the Value of Packaging Finding balance between consumer preferences/attitudes - Demand value, performance and sustainability with NO compromises and the role of packaging! - Must win at shelf, communicate info, protect & preserve, extend shelf life, be convenient & safe to use, support efficient logistics, sustainable

5 Packaging Innovation Gateway - One of most popular articles of past months - More than 2,000 page views - Keep building this momentum

6 Case Studies From Members What would be recycling impact of switching from PET to talc-filled polypropylene tray and OPS lid for Home Meal Replacement products? Recycling comparison of metal vs. plastic aerosol containers Recycling impacts of using a full-wrap label on polypropylene tub

7 Sustainable Packaging Award Winners

8 Released April 4 th, 2016 Input from project committee of 30+ members Subject matter experts across the packaging value chain 5 new packaging formats Top Packaging Challenges Revisited

9 Top Packaging Challenges Revisited PACKAGE DESIGN SORTING TECHNOLOGY END MARKET VALUE CONSUMER ENGAGEMENT Addresses impact area(s) with explanation Reference latest studies and best practices

10 Top 15 Packaging Challenges in a MRF 1. Multi-Layer Laminates (mixed plastics resins and foil) Not recyclable but consumers put in bin Manual sorting - goes to residuals for landfill or EfW Volume impact 10 pouches = 1 bottle Flexible laminated packaging demand growing Need viable recycling end market 2. Compostable Plastic (mainly PLA) Not accepted curbside but similar to clear PET / PS Optical sorters divert to mixed plastics Manual sorting similar to PET PLA no longer sold into beverage bottle market Focus on recycling NOT on composting 10

11 Top 15 Packaging Challenges in a MRF 3. Black Plastic Containers Variable acceptance curbside Manual sorting to mixed plastics (Optical sorters not effective) Other colors preferred or additives easier to sort 4. Full Shrink Wrap Label Accepted curbside Full labels can confuse optical sorters APR Design for Recyclability guidelines - Label floats in water - Ink does not stain rpet - Partial label preferred 11

12 Top 15 Packaging Challenges in a MRF 5. Hot Beverage Polycoated Cups Variable acceptance curbside Keep lid separate from cup rinsed / clean Manually sorting to polycoated containers (high value) or mixed paper stream (lower value) Optical sorters for fibers then manual sort 6. Metallized Tubes Not accepted curbside but consumers put in bins Ends up in residuals going to landfill or efw Enval developing technology to separate foil / plastic 12

13 Top 15 Packaging Challenges in a MRF 7. Single-Serve Hot Beverage Pods Not accepted curbside but consumers put in bin Small contaminates glass stream Design for dis-assembly, recyclable plastics and compostable plastics 8. Colored Opaque PET Accepted curbside but contaminates clear PET Requires manual sorting to mixed plastics Clear PET preferred 13

14 9. Non-PET Clamshells Similar to clear PET Optical sorters send to mixed plastics APR guidelines use labels, inks & adhesives that can be easily removed 10. Corrugated Tray with Plastic Film Requires manual separation of materials otherwise plastic & board goes to landfill Municipality P&E programs separate materials or avoid mixed materials Top 15 Packaging Challenges in a MRF 14

15 *11. Caps on Plastic Bottles Mixed messaging to leave caps ON or OFF led to consumer confusion Loose caps are more likely to end up as litter or may contaminate glass if entering recycling stream End markets exist for PP from the caps *12. Labels on PET Thermoforms Top 15 Packaging Challenges in a MRF Re-processor issue where ink, adhesive and label can contaminate rpet flake if it cannot be washed off properly Guidelines and protocol available for these labels 15

16 *13. Glass Jars and Bottles Single stream results in low grade glass that is difficult to color sort Successful deposit programs exist for glass bottles *14. Plastics Bags and Films Top 15 Packaging Challenges in a MRF Curbside collection is less preferred than takeback/depot due to higher contamination Films/bags wrap around mechanical machinery causing inefficiencies (shutdowns) at a MRF 16

17 *15. Polycoated Containers Aseptic and gable top cartons are typically reprocessed into high value fiber whether manually or optically sorted. MRFs of different types (single or dual steam, using automated or manual sorting) are encouraged to sort polycoated cartons into their own grade for recycling to retain economic value Top 15 Packaging Challenges in a MRF 17

18 PAC Decision Trees & Design Guides Helpful Links: - PAC NEXT Decision Trees - APR Design Guide for Plastics Recyclability 18

19 Packaging Innovation Gateway Process Inputs current, modified, new package designs widely recycled Yes action plan Innovation Gateway panel review & assessment re-assess No re-design alternate approach Maybe harmonize material acceptance alternative collection methods MRF sorting technology re-processing solutions develop end markets partial re-design communication & education 19

20 Thank you! Rachel Morier, BTech, MES Program Manager, Packaging & Food Waste Learn more at pac.ca!