Top 10 Packaging Challenges For Recycling in a MRF ......10 Top 15 Packaging Challenges in a MRF 2....

Top 10 Packaging ChallengesFor Recycling in a MRF

REVISITED

8th Canadian Waste Resource SymposiumApril 28th, 2016

The Way

VISIONA World Without Packaging Waste

GOALTo minimize system recovery costs

while maximizing recycling rates andthe value of recovered materials

Optimizing for the Packaging Value ChainNegative

environmentalimpact

Increasingpackaging

material useMinimum material

OverpackagingUnderpackaging

Optimum PackDesign

Minimumenvironmental

impact

Diagram courtesy of Innventia AB

Finding Balance

• 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, supportefficient logistics, sustainable

Product Design & the Value of Packaging

Finding Balance

- One of mostpopular articlesof past months

- More than 2,000page views

- Keep buildingthis momentum

Packaging Innovation Gateway

• What would be recycling impact ofswitching from PET to talc-filledpolypropylene tray and OPS lid forHome Meal Replacement products?

Case Studies From Members

• Recycling impacts of using afull-wrap label on polypropylene tub

• Recycling comparison of metal vs. plasticaerosol containers

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Sustainable Packaging Award Winners 2015

Top Packaging Challenges Revisited

• Released April 4th, 2016• Input from project

committee of 30+members

• Subject matter expertsacross the packagingvalue chain

• 5 new packaging formats

Top Packaging Challenges Revisited

• Addresses impact area(s) with explanation• Reference latest studies and best practices

PACKAGEDESIGN

SORTINGTECHNOLOGY

END MARKETVALUE

CONSUMERENGAGEMENT

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

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Top 15 Packaging Challenges in a MRF

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

3. Black Plastic Containers• Variable acceptance curbside• Manual sorting to mixed plastics

(Optical sorters not effective)• Other colors preferred or additives – easier to sort

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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

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

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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

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

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8. Colored Opaque PET• Accepted curbside but contaminates

clear PET• Requires manual sorting to mixed

plastics• Clear PET preferred

Top 15 Packaging Challenges in a MRF

9. Non-PET Clamshells

• Similar to clear PET• Optical sorters send to mixed plastics• APR guidelines – use labels, inks &

adhesives thatcan be easily removed

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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

*11. Caps on Plastic Bottles

• Mixed messaging to leave caps ON orOFF led to consumer confusion

• Loose caps are more likely to end up aslitter or may contaminate glass if enteringrecycling stream

• End markets exist for PP from the caps

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*12. Labels on PET Thermoforms• Re-processor issue where ink, adhesive and

label can contaminate rPET flake if it cannot bewashed off properly

• Guidelines and protocol available for theselabels

Top 15 Packaging Challenges in a MRF

*13. Glass Jars and Bottles

• Single stream results in low grade glass that isdifficult to color sort

• Successful deposit programs exist for glassbottles

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*14. Plastics Bags and Films• Curbside collection is less preferred than take-

back/depot due to higher contamination• Films/bags wrap around mechanical machinery

causing inefficiencies (shutdowns) at a MRF

Top 15 Packaging Challenges in a MRF

*15. Polycoated Containers

• Aseptic and gable top cartons are typicallyreprocessed into high value fiber whethermanually or optically sorted.

• MRFs of different types (single or dual steam,using automated or manual sorting) areencouraged to sort polycoated cartons intotheir own grade for recycling to retaineconomic value

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Top 15 Packaging Challenges in a MRF

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PAC Decision Trees & Design Guides

Helpful Links:- PAC NEXT Decision Treeshttp://www.pac.ca/KCSearch.cfm- APR Design® Guide for Plastics Recyclabilityhttp://www.plasticsrecycling.org

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Packaging Innovation Gateway Process

Inputscurrent, modified,

new packagedesigns

panel review &assessment

InnovationGateway

Yes No

Maybe

widely recycled re-designalternate approach

action planre-assess

• harmonize material acceptance• alternative collection methods• MRF sorting technology• re-processing solutions

• develop end markets• partial re-design• communication & education

Thank you!

Rachel Morier, BTech, MESProgram Manager, Packaging & Food Waste416.727.3512rmorier@pac.ca

Learn more at pac.ca!