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Flexible Plastic Packaging Sustainability: Will the
Industry be Ready for2025?
Pierre Sarazin AIMCAL R2R Conference &SPE FlexPackCon
Myrtle Beach, SC – October 6-9,2019
A Closer Look at Plastic Sustainability
• In nature, there is no concept of waste• We should try to not only protect, but actively improve the environment
• Design is at the root to prevent waste and pollution• Around 80% of environmental impacts are the consequences of decisions made at the design stage• Eliminate unnecessary plastics
• Be able to close the loop on packaging materials so they don’t end up in landfill• Recycling, composting
https://www.ellenmacarthurfoundation.org/circular-economy/what-is-the-circular-economy
Cradle-to-gate
2
Cradle-to-grave
Cradle-to-cradle** or closed loopproduction
• Life cycle assessment is the key• Difficult to determine what is the best for the environment without the full
picture• Unfortunately, the general public only deems the plastic sustainability to
the visible waste generated
What is Awaiting the Packaging Industry?
2026 2028 20292022 2023 2024 20252020 2021 2027 2030
Ocean Plastics Charter(06/2018)
21 governments, 60 businesses &
organizations so far• 100% reusable, recyclable, or, where viable
alternatives do not exist, recoverable plastics• Recycled content by at least 50% in plastic
products where applicable• Recycling and reuse of at least 55% of
plastic packaging• The recovery of 100% of all plastics by 2040
3
20AA
http://www.wrap.org.uk/content/what-uk-plastics-pact Pacte National sur les emballages plastiques, Ministère de la TransitionÉcologique et Solidaire, République Française, Février 2019 A European strategy for plastics in a circular economy, European Commission, 2017 https://www.canada.ca/content/dam/eccc/documents/pdf/pollution-waste/ocean-plastics/Ocean%20Plastics%20Charter_EN.pdf
1 European Strategy for Plastics in a
Circular Economy(Started in 12/2015, Adopted 01/2018)
• All plastics packaging placed on the EU market is either reusable or can be recycled in a cost-effective manner
• More than 50% of plastics waste generated in Europe is recycled
• Sorting & recycling capacity x4 compared to 2015
Ellen MacArthur Foundation’s NPE
UK (04/2018),
2
FR (02/2019), Chile (04/2019)
1. Eliminate problematic plastic packaging
2. 100% of plastic packaging isreusable, recyclable, or compostable
3. 60% recycled in 2022 (F), 70%effectively recycled or composted in 2025 (UK)
4. Increase recycled content in plastic packaging (30% average)
3
What is Awaiting the Packaging Industry?
2026 2028 20292022 2023 2024 20252020 2021 2027 2030
20AA
New Plastic Economy, Global Commitment, June 2019 Report: https://www.newplasticseconomy.org/about/publications/global-commitment-spring-report
(10/2018)1. Priority: elimination of problematic or unnecessary plastic2 . Reuse models are applied where relevant3. All p last ic packaging i s 100% reusable , recyclable, or
c omp os t a b l e4. All p last ic packaging i s r eused, recycled, or c omp os t ed
in pract ice5. The use of plastics is fully decoupled from the consumption
of finite resources6. All plastic packaging is free of hazardous chemicals, and the
health, safety, and rights of all people involved are respected
4
4
NPEC• Today’s focus:
Global Commitment: Overview of Bus iness Signatories
• Business signatories account for more than 20% of global plastic packaging volumes• The tracking of the advancements is to be reviewed every 18 to 24 months
New Plastics Economy Global commitment – June 2019 Report, 235 pages, June 17, 2019
CPG compagnies: 6 of the top10global fast moving consumergoods (FMCG) companies
Plastic packaging producers:7 of the top 10global producers
Recyclers and other afteruse
Retail & hospitality: 5 of the top 15global retailers
Durable goods producers Suppliers to plastic packaging industry
Raw material producers: almost exclusively in compostable plastics
Investors
CPG compagnies: 6 of the top 10 global fast moving consumergoods (FMCG) companies
Retail & hospitality: 5 of the top 15 global retailers
5
Concrete Actions Taken by CPG Companies & Retailers
• Several companies have no real claimed concrete actions so far…• In the report, their commitments are split in 5 categories:
Take action to eliminate Take action to move from 100% of plastic packaging Set an ambitious 2025* Commit to collaborateproblematic or single-use towards reuse to be reusable, recyclable, post-consumer recycled towards increasing reuseunnecessary plastic models where relevant by or compostable by2025* content target acrossall /recycling/compostingpackaging by 2025* 2025* plastic packaging used rates for plastics
• Focus on the companies below for categories #1, #3,#4:• CPG companies above $ 10bn annual revenues• Retail & Hospitality companies above $ 1bn annual revenues
1 432 5
New Plastics Economy Global commitment – June 2019 Report, 235 pages, June 17, 2019 *2025 refers to December 31, 20256
Eliminate Problematic Plastic Packaging
Resin & Structure changes Other actions
CPGcompanies
• Phase out PVCquickly• PS, EPS, PVdC, coloured PET also
targeted• Eliminate oxo-degradable• Alternative to incompatible
multilayers• Alternative to black plastics or
detectable black
• Eliminate plastic bags• Alternative to plastic straws• Food compaction• Eco-design• Optimize packaging in e-commerce• Decrease packaging weight
Retail & Hospitality companies
• Phase out PVC, PVdC,EPS• Prohibit the useof oxo-degradable• Convert shrink wrap to LDPE• Reduce / eliminate fossil-based
plastics• Convert plastic to paper &
cardboard (bag closure, blister)
• Reduce single-use plastic bags; Replace by reusable / paper / biodegradable shopping bags
• Charge for plastic bags• Phase out plastic in straws & disposable items, plastic cutlery,
cotton swabs• Identify / reduce unnecessary packaging for fruits & vegetables• Remove non-recyclable for organic fruits/vegetables• Reduce packaging use for fresh products (ex: cheese plastic trays)• Reduce the thickness• Alternative solutions for food trays and structural packaging• Re-design
1
New Plastics Economy Global commitment – June 2019 Report, 235 pages, June 17, 20197
100% of Plastic Packaging to be Reusable , Recyclable, or Compostable
Resin & Structure changes Other actions
CPGcompanies
• Phase out or be able to convertopaque PET
• Develop a recycling stream for PS• Recycle PP and use rPP• (Compostable)• Eliminate multilayers
• Recyclable paper bags• Eliminate caps, labels• Eco-design• Make plastics out of pyrolysis feedstock & chemical recycling
Retail & Hospitality companies
• Transition from PS, PVC,black plastic to recyclablematerials
• PP bakery bags to home-compostable cellulose bags
• Printing with vegetable-based ink (carboardpackaging)• Replace plastic trays by PET or cardboard trays• Use monomaterials where possible• Plastic collection• Home compostable• 50% rPET content for all baking trays• Recyclable shopping bags with 80% recycledcontent
3
New Plastics Economy Global commitment – June 2019 Report, 235 pages, June 17, 20198
Set an Ambitious 2025 PCR Content Target
Resin & Structure changes Other actions
CPGcompanies
• rPET• rPE• PCR Food grades
• 20% to 100% PCR• Target secondary and tertiary packaging• Use pyrolysis, chemical recycling
Retail & Hospitality companies
• Replace PLA with rPET! • 20 to 50% recycled content in the packaging on average• PET: 25 to 85% rPET• Reusable plastic bags made from plastic collected in the stores• Renewable based plastics• Meat trays with 50%recycled• Trash bag with 100%recycled
4
New Plastics Economy Global commitment – June 2019 Report, 235 pages, June 17, 20199
Initiative: Example of Walmart
APR-Plastics design for recyclability webinar series – Part 1: an overview of plastic packaging, July 11, 2019
• Packaging is one pillar of the Project GigatonTM, for which Walmart clearly describes its sustainability priorities
• “For private brands, encouraged for national brands”
• Education: from July to end of October 2019, a series of 6 webinars hosted byWalmart and presented by theAPR
Signatory of the
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walmartsustainabilityhub.com
Walmart’s Sustainable Packaging Playbook
• Are described the best practices for suppliers to help identify ways toimprove packaging recyclability:
• Package designed with PET, HDPE, LDPE, LLDPE, P P• Preferably natural, lighter or transparent color• No degradable additives added• Label, closure, attachments of the same resin a s the package• PCR content (typically at least 20%)
□ Recyclable at retail drop-off□ LDPE, MDPE, LLDPE, HDPE□ Unpigmented is best or white or light
colors□ No degradable or biodegradable
additives□ Ensure density of blend is less than 1□ Labels in PE or directly printed□ Currently no minimum PCR content
□ Recyclability challenges• Food-contact packages : design for easy cleaning• Multi-material packages (not all PE): use recycling
compatible options• Materials: any non-PE resins mixed in, dark colors,
PVC, PVdC, metalized layers, fillers altering the filmdensity (>1), starch resins, degradable additives
• Attachments, c losures: challenges with metal, foils, PET, PLA, PP, PS, PVC
• Labels: the same + metalized printing, paper
PE ba gs and Films
11
Ships everywhere in North America
QUEBEC, CAN
• 100 000 sq ft facility
• 14 extrusion lines
PolyExpert Inc.
https://www.polyexpert.com/enSatellite Warehouses
What About PolyExpert?
12
Consumer
Retailer
Food Service
Health Care
Provider
Co-packer
Consumer Packaged
Goods CompanyConverter
MaterialSupplier
Equipment Supplier
PolyExpert in the Packaging Value Chain
From B.A. Morris, The science and technology of flexible packaging, Multilayer films from resin and process to end use, 2017, Elsevier
Printing, lamination, sealing…
Manufacturer of blown films
End of life options:
Recycler
Composting
Converter
13
Product Sustainability at PolyExpert
• Select R&D projects by focusing on sustainability
• Ecoresponsible Certification: Level 2 «Performance» in progress
Plasticpackaging vs. Substitutes
Plastic recycling innovations
Flex. Food Pack. Circular Economy
Biodegradables & Oxo-degradables
Recycled & Compostable
resins
Downgauging(HDSS, MWPB)
Transition to PE for
recyclability
Transition to Flexible
(sealant webs) Sustainability Barrier
Structures
14
• Educational presentations for our team & our customers
Product Sustainability at PolyExpert: Resin Sources
• Post Industrial (PI)• From film retains or unused bags□ PolyExpert uses PI resins in several film products ranging from 25 to 70%□ Secured PI supply
• PCR• From bags and packaging products retrieved from various recycling
processes after consumer usage□ PolyExpert is making films with 25 to 95%□ Secured PCR supply• Upcoming FDA PCR trial
• Compostable plastics□ The design is applied to the product or packaging a s a whole□ The facilities to compost the films are existing (specific applications)□ The product would not be recycled anyway e.g. due to contamination
• PolyExpert already produces films with these resins (several millions lb/year)
15
What We Tell our Customers
• Not a unique solution!• The complete value chain of the packaging should be examined• The complete packaging must be examined• It will imply a change: process, aspect, cost…• Should be addressed:
• What is the end of life of the product?• If it was recyclable, could it be recycled?• If it was compostable, could it be composted?• What are the properties that could be changed?• Converting the film: do you have room for process modification?
• What would be the perception of the end-users?
“Why do you want to
improve the packaging
sustainability?”
16
Will the Industry be Ready for 2025?
• Hard to say after just one year of the Global Commitment and six years ahead of us• We need more concrete implementation• Is more persuasion needed?
• UK: Tax on plastic packaging containing less than 30% recycled content, starting April 2022• Portugal: no tax for plastics over 2 mils incorporating at least 70% recycled
What will it take:
Raw Materials
Residual Waste
Let’s discuss tomorrow morning!
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• SPE/FlexPackCon
• October 8th, 8:30 AM
“Flexible Food Packaging in the Context of Circular Economy”
Will the Industry be Ready for 2025?
What is your opinion?
Raw Materials
Residual Waste
18
Thank you!Pierre SarazinR&D Manager & Technical Services psarazin@polyexpert.com1 877 384-5060
www.polyexpert.com
Thanks to Nathalie Laganière, Florence Perrin andEmma Sarazin for their assistance in reviewing this presentation
Websites
• CEFLEX (Circular Economy for FLEXible packaging) https://ceflex.eu/who-we-are/• APR (Association of Plastic Recyclers) https://plasticsrecycling.org/• Sustainable Packaging Coalition (SPC)https://sustainablepackaging.org/• The Recycling Partnership (US) https://recyclingpartnership.org/• TerraCycle’s & Loop https://www.terracycle.com/en-US &https://loopstore.com/• How2Recycle label https://www.how2recycle.info/• On-Pack Recycling Label https://www.oprl.org.uk/• Materials Recovery for the Future https://www.materialsrecoveryforthefuture.com/• Flexible Packaging Europe https://www.flexpack-europe.org/en/fpe/home.html
Re ferences
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2. Move from single-use towards reuse models
New Plastics Economy Global commitment – June 2019 Report, 235 pages, June 17, 2019
Resin & Structure changes Other actions
CPGcompanies
• … • Reusable/refillable packaging• Concentrate the packaged products• TerraCycle’s Loop trials
Retail & Hospitality companies
• … • Reusable bags• Choice of reusable packaging for fresh products (bread, meat,
seafood, deli)• TerraCycle’s Loop for e-commerce
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5. Commit to collaborate towards increasing reuse/recycling/composting ra tes for plastics
Collaborations
• Drop-boxes & improve access to collection• Consumer education• Take part to Bio-PETdevelopment
CPGcompanies
Retail & Hospitality companies
New Plastics Economy Global commitment – June 2019 Report, 235 pages, June 17, 2019
• Curbside recycling for flexible packaging:
• The European Forum for the Flexible Packaging Industry:
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