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Things to Consider Before Adopting PCR in Your Packaging

Dec. 02, 2024

Factors to Ponder Before Integrating PCR into Your Packaging Solutions

Post-Consumer Recycled (PCR) plastic packaging is emerging as a eco-friendly packaging alternative aimed at reducing environmental hassles caused by product waste. Numerous prominent global brands are declaring their commitment to sustainability by incorporating PCR plastics. However, before you decide to implement this solution, it is imperative to understand the potential challenges you may encounter with PCR plastics. While PCR is a step forward, it also has its share of advantages and disadvantages that must be considered. Let's begin by outlining the fundamentals.

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Understanding PCR Plastic

PCR, which stands for Post-Consumer Recycled, is also sometimes referred to as Post-Consumer Resin. PCR plastic originates from the recycling of used plastics, turning them into end products. Among the available types of plastics, high-density polyethylene (HDPE) and polyethylene terephthalate (PET) are the most frequently used for PCR materials. Though polypropylene (PP) is less commonly collected in recycling processes compared to HDPE and PET, its demand is on the rise alongside the other two materials. The advantages of PCR are evident, including a decrease in overall carbon emissions and a reduction in waste and the consumption of virgin materials. It is crucial, however, to acknowledge the challenges linked to utilizing PCR in order to make informed decisions. To grasp these challenges, we first need to understand how PCR is produced.

The most prevalent method for recycling plastics is mechanical recycling, a process that includes various stages such as sorting, cleaning, shredding, melting, and remolding. After undergoing mechanical recycling, used plastics transform into PCR resin, which can then be employed to manufacture new plastic products.

Key Considerations

Consideration 1: Quality of PCR Materials

Plastics are generally composed of polymers with intricate long-chain structures made of various elements like carbon, hydrogen, oxygen, and nitrogen. During the recycling process, these polymer chains can degrade, which poses a challenge in creating packaging that consists of 100% PCR without sacrificing durability and performance, as compared to packaging made from virgin resin. Most plastics can endure only a limited number of recycling rounds before becoming unusable. Nonetheless, innovations in PCR have made it possible to create 100% PCR packaging with commendable performance, as evidenced by the packaging designed for Colgate-Palmolive dish soap. However, this degradation remains one of the main obstacles associated with using PCR.

Consideration 2: Purity of PCR Materials

Furthermore, recycling isn't just about collection—quality is paramount. Different plastics have distinct chemical and physical attributes and applications. Consequently, the collected plastics encompass a variety of materials, shapes, sizes, and colors. Even with thorough sorting, PCR resin may still contain certain impurities. Thus, the quality of recycled plastics is critical for acceptance during reprocessing. In addition, brand owners seeking to utilize PCR materials face challenges related to securing a reliable supply of high-quality PCR.

Consideration 3: Availability of PCR Materials

Lastly, as previously mentioned, the supply of PCR plastics currently fails to meet the rising demand. According to Waste Management, around 25% of the items that consumers place in recycling bins fail to get recycled due to contamination. While many individuals acknowledge the significance of recycling, there's still a widespread lack of understanding regarding the proper recycling methods.

The current landscape of the US PCR market has been outlined over the past five years, particularly concerning polyethylene and recycled PET.

In a significant policy shift, China ceased the importation of nearly two billion tons of plastic waste annually. This change compelled the world to confront the magnitude of the global waste crisis. Between 2018 and 2020, governments enacted policies to diminish the reliance on virgin plastics, and brands pledged towards achieving circularity. While this marks a commendable beginning, the challenges in supply and demand remain critical.

Current and Future PCR Market:

Supply

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The existing supply of PCR for packaging applications is not expected to fulfill the anticipated demands in the upcoming years.
Recycling, recovery, and collection of waste are increasingly becoming economically appealing opportunities. Major corporations like KW Plastics are making investments to enhance both supply volume and quality.
Trend shifts towards sustainable, recyclable packaging are ultimately paving the way for a high-quality circular supply.

Demand

New digital marketplaces are providing buyers and sellers with unprecedented opportunities for more accessible trading.
PCR packaging is effective in minimizing the need for raw materials and curtailing the volume of plastics dispatched to landfills.
The demand for PCR is rising in tandem with increased oil prices and general disfavor towards traditional plastics.

The graph below illustrates the declining trend of plastics and resins indices since October 2020, primarily influenced by inflation-driven supply chain challenges.

Conclusion

In summary, PCR plastics represent a sustainable option worth considering. However, it's vital to be mindful of the challenges at hand and treat PCR as one of many avenues to achieve sustainability goals. With over 50 years of experience in the flexible liquid packaging sector, ZACROS brings expertise and innovative solutions to the table. Contact us to learn more about our offerings and insights.