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Recycled PET (rPET) in Retail Packaging
Recycled PET (rPET) in Retail Packaging
Agenda
Jennie Price WRAP Paul Davidson WRAP Karel Wendl The Coca-Cola Company Edward Kosior Nextek Mark Caul M&S Peter Skelton WRAP John Simmons Recoup
WRAP
Jennie Price CEO WRAP
WRAP:
Private company, funded by DEFRA and the devolved administrations Set up in 2001 from Waste Strategy 2000 200 staff, 7 programmes Helping businesses and the public to reduce
waste, to use more recycled material, and recycle more things more often
Consumer: engagement
Recycling Kerbside collection On-pack messages Mass media
Overview
UK PET packaging consumption UK bottle collection rates and trends Accelerating collection growth End destination for collected bottles Potential rPET reprocessors rPET availability Environmental arguments for rPET Exports Other polymers? Conclusions
Target Ten
New Plastics collection strategy for WRAP Have concentrated on new schemes and scheme conversion Now have 86% of UK authorities offering some sort of plastic bottle collection Current UK kerbside plastic bottle collection average is 5kg/hh/yr Average UK household uses 20-25kg/yr Want to get average to 10kg/hh/yr Participation Want All plastic bottles
Reprocessing
Export 75% UK 25%
15%
Waste Management
c85%
Landfill or incineration
Reprocessing
Export UK
30%+
Waste Management
Landfill or incineration
Total mixed bottle collection Current UK rPET usage - locked in Current UK rPET demand
Potential rPET output Current UK rPET usage - other Phase 2 projected UK rPET demand
LCA Selection
Material Number of studies evaluated 19 29 108 42 19 31 24 Number of studies used 11 3 9 10 11 9 2 Number of scenarios identified 25 7 63 60 20 20 6 Glass Wood Paper and cardboard Plastics Aluminium Steel Aggregates
Recycling vs Landfill
Recycling vs Incineration
LCA Conclusion
Recycling 1 tonne of Plastic bottles saves:
Exports
Chinese demand has been very strong for plastic bottles over last 3 years High proportion of UK bottles currently exported Demonstrates UK is very open market Bottles are available if price is right PET bottle demand from China has softened over last 6 months rPET market removes the need to export
Other Polymers?
WRAP has developed a process for reprocessing HDPE back to food grade Currently undergoing extensive testing and trials Should work for other polymers particularly PP Would need collection infrastructure to be developed
Conclusions
Rapidly changing situation for rPET in UK Collection Reprocessing infrastructure Demand Strong environmental imperative to use Good LCA data Provides a new opportunity to the UK for an environmental and economic win
paul.davidson@wrap.org.uk
Thank you
Post-Consumer PET in Direct Food Contact Applications Global Challenges and Commercial Experiences
WRAP Conference London, UK
February 6, 2007
Topics
The Past: Establishment of guidelines/safety The Present: Availability of post consumer material Processing for non-food and food applications Global regulatory status Commercial experiences using recycled PET in bottle-to-bottle applications
The Past
Historically, industrys interests in food applications for Post consumer recycle plastics started in the late 1980s In general, regulatory agencies had no provisions to deal with this request In the United States, Industry and the FDA met to begin discussing acceptable approaches for the use of PCR Plastics in food applications
The Past
Traditional risk assessment is based on knowing the identity of potential contaminants With post consumer plastics, the dilemma was that the potential contaminants were unknown
The Past
FDAs approach with industry input was to establish robust surrogate testing demonstrating surrogate removal below a level of concern FDA formally established their industry guidelines in May 1992
Guidelines employed the concept of the Threshold of Regulation
The Past
The FDA guidelines established the key criteria for assessing the safety of particular technologies being considered
Surrogate contaminants Time duration of surrogate exposure target end results for the tests
WHERE WE ARE ?
Numerous scientific investigations have been conducted and created an excellent database to establish the safety of PCRPET in food use applications:
Barrier layer inhibition of contaminant migration Effects of contaminant removal via washing Effects of contaminant removal via extrusion Effects of contaminant removal via super cleaning Composition of the PCRPET feed stream Absorbed Compounds in the PCRPET feed stream Statistical evaluation of the European PET feed stream establishing the basic absorbed compounds, their levels and the relative degree of incidental contamination
WHERE WE ARE ?
ILSI Europe Packaging task force developed similar guidelines in 1998 Many countries in Europe, Latin America and Asia have reviewed the science, and established their own guidelines\criteria for use of PCR PET in food applications EU regulation on recycling has been drafted based on two EU funded FAIR projects, and hopefully will be approved in 2007
WORLD
PET Packaging Demand
40 35 30 Million tons 25 20 15 10 5 00 1992 1997 2002 2007 2012 2017
1992-2017
33.1
Citizen demand
Year
45%
39.7%
700 600 500 400 300 200 100 0 1995 1996 1997 1998 1999 2000 2001 2002* 2003 2004
21.6%
Amount Collected
Recycling Percent
000 Tonnes
Volume collected in 2004 was 31.8% higher than in 2003! 2005 was 19.8% higher than 2004!
Incremental volumes from :
Market growth Collection / sorting efficiency gains
2001
AJN1072/ at
2002
2003
2004
2005
2006
Source: PCI/PETCORE
2000
2109
1500
Post Consumer PET Virgin PET
1000
500
76%
283
20% 100%
80 39
Strap Sheet
4%
75
Beverage Bottles
59%
9.2
Injection
0 Fibres
Source: PETCORE
Final Grinder
Size: 8mm
Metal Detector
Al Cap, etc. removal
Debaler
Label Separator
Label removal
PVC Separator(X-ray)
PVC Bottle
Flake Washer
Caustic: 3% 85 C - 20min.
Storage
Shipping IV=0.76
Vibrator
Dryer
Flake Feeder
Hydro Cyclone
PE,PP removal
Pelletizer
600 mesh
Inspection Conveyor
3 Operators/line
Rinse Washer
First Grinder
Size: 50mm
Flash Dryer
Pellet Packer
Aluminum Detector
Gravity Separator
Label removal
Storage
Shipping IV=0.73
New Bottles
PET FLAKE
GRIND WASH
3. MONOLAYER
GRIND WASH
PET FLAKE
SUPER CLEANING
MONOLAYER
GRIND WASH
PET FLAKE
MONOLAYER
DECONTAMINATION PROCESSES
HEAT VACUUM SUPER CRITICAL FLUIDS SURFACE AREA SOLVENTS SURFACE CHEMICAL TREATMENT
1 9
13
USA Survey:
87% of consumers think its good for beverage companies to use recycled content in plastic bottles
Japan Survey:
90% of consumers either preferred or said it did not matter if the bottle had recycled content Note 1. Countries surveyed: Austria, Belgium, France, Germany, Italy, Spain and the UK
Limonene
Unprocessed
Processed
17
MONOLAYER
17
Our Coca-Cola System has been using various PET Bottle-to-Bottle recycling technologies, since 1991: Multilayer, Depolymerization, Monolayer:
IN 13 COUNTRIES OVER 16 YEARS, WITH STRICT REQUIREMENTS SINCE THE START! => NO MARKET QUALITY ISSUES!
Food Grade Recycled PET: Technical Issues Introduction to Nextek Limited Food safety of Recycling processes . rPET recycling technology for making food contact packaging from waste Quality issues Contamination, Colour, Impurities rPET issues, Sheet, bottle, water, CPET Future challenges for (recycled) plastics packaging
RECENT UK Projects
Development of PET recycling plant for Closed Loop London Development of a new FDA Food Grade PET Recycling Process Demonstration of Viability of rPET in Retail Packaging: CLL, M&S and Boots Beverage Packaging Waste Reduction: Light weighting PET bottles, Esterform Using Post-Consumer Tyres in a Range of New Applications: Pipe Sealing System Development of Light Weight Compostable Packaging- Sainsburys Demonstration trial of Recycled HDPE into Milk Bottles- WRAP
Chemical Recycling
Breakdown of PET into Basic building blocks, purifying and re- polymerising back to Virgin PET
Multi-Layer processing
Requires a virgin layer in the final application in contact with food. At least 25 micron layer for T room temp At least 50 micron layers for T room temp PET preforms/Bottles require tooling with Co-injection capability ( Owens Illlinois , Hofstetter, Kortec) Sheet and thermoformed products require 3 layer tooling and sufficiently thick virgin layer to ensure that at least 25 microns remains at the thinnest section
10/80/10 Virgin/rPET/Virgin
30/40/30 Virgin/rPET/Virgin
US FDA regulations
Threshold of Regulation- USA Plastics for food contact are always evaluated for any migration that might occur when in contact with food material. migrating substances are considered to be food additives. Threshold of Regulation -a level below which the probable exposure to a potentially toxic substance is a negligible risk (defined as 0.5ppb in daily diet) US FDA Validation of Recycling Processes Any recycling process must demonstrate its ability to remove potential contaminants due to consumer misuse. A series of representative chemicals or their surrogates are used to spike PET flake in a Challenge Test. 100% of flake is contaminated for 2 weeks at 40 deg C. (Flake absorb up to 10 times more contaminants than bottles) Mathematical migration modeling is now accepted instead of some testing and approvals.
Total Safety Factors 1000x 10,000 x 10 x 10 x 2 = >2x 10 ie >2 billion times safety factor
Decontamination results
Rt = 1.8 min, Acetaldehyde Rt = 2.5 min, 2-methyl-1,3-dioxolane Rt = 2.9 min, ethylene glycol Input Flake
Washed Flake
Decontaminated Flake
Conversion to bottles
Virgin PET
50% rPET
Input Moisture Iron wires Labels Manual sorting Metal separator Dust Coloured particles Caps Waste in waste water Total waste PET flakes
Sorting Bottles and Flakes with Visible and Near Infra Red (NIR)
Sorters NRT Mikrosort MSS Rofin RTT S+S Satake Titech Unisensor
Reflection
Transmission
Page: 09
UNISORT PX
Ein Gert drei Fraktionen
UNISORT Section 3
Ein Sensor drei unterschiedliche Sortiersektoren Sensor
Section 3 Section 2 Section 1
PET
positive Austrag
HDPE
Durchlauffraktion / Reste
Reste
1. Separation of flakes into a planar stream 2. Capturing visible of spectral data from light source reflected or transmitted 3. Visible light, NIR and laser are in use for flake sorting 4. Analysis of data 5. Operation of ejectors in synchronisation with flake velocity 6. Recycling of reject stream to increase recovery rate.
SORT FLAKE
DECONTAMINATION
SINK-FLOAT in water
DRY/AIR CLASSIFICATION METAL REMOVAL
Ecoclear (Wellman)
EcoclearTM is manufactured by Wellman using a proprietary process based upon automated sorting and chemical / thermal cleaning of food grade bottles from collection systems. EcoclearTM recycled content PET resin (25% RPET:75% virgin PET) for beverage containers and sheet is produced at Wellmans 50,000 tonne / year Emmen site in Holland.
Vacurema (Erema)
The Erema TE-VSV (VacuRema) process converts clean dry bottle flake to crystallised food grade pellets and can also produce a melt for direct extrusion to a finished product . The VacuRema system has approval from Pepsi USA and in Germany, Switzerland and Austria, with food contact approval applied for in Canada, Hungary and Brazil. Newer versions of the VacuRema use 3 vacuum reators for further control over the IV. The VacuRema process can increase viscosity up to virgin material levels e.g. typically to 0.77 to 0.84 dlg-1
Stehning (OHL)
The OHL Stehning bottle to bottle process consists of the following main stages: Washing and grinding: hot water/steam pre-wash, automatic sort system, wet grinding and several intensive washing operations before flash drying. The flakes then enter a further grinding stage for final size reduction. The dry flake feed is fed to modified extrusion system (vented multi screw extruder) where volatiles are partially eliminated contaminants are melt filtered before regranulation. Solid State polycondensation (SSP) in a batch reactor (vacuum rotary dryer) eliminates volatile by-products such as glycol, acetaldehyde and oligomers, raises the IV. from (~0.70 dlg-1 to ~0.82 dlg-1) and converts the amorphous PET to crystalline PET.
The key process stages are: sorting, hot washing decontamination, filtration, granulation, drying, crystallisation and solid state polycondensation. The technology involves the Bhler Ring Extruder and continuous Solid State Polycondensation (SSP) processes. The first Bhler line was installed by Amcor in Beaune, France in 2001. The plant has an annual output capacity of 20,000 tonnes per year.
1 2 3 4 5 6 7 8 9 10
100% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00%
Introduction
Governing principle The legislation Its main provisions Future Recycling Regulation When Questions
Governing Principle
All food contact materials:
Manufactured according to good manufacturing practice Not allow constituents to migrate into food in quantities: - harmful to human health - affect nature/quality of food
The Legislation
European Commission Directive 2002/72/EC & four amendments plus 1 other on vinyl chloride monomer and two on migration test methods The Plastic Materials and Articles in Contact with Food (England) (No.2) Regulations 2006
Main Provisions
OML 60 mg/kg food
SMLs for individual substances Offences and defences Penalties Compliance declarations Migration test methods
When?
current proposal began in October 2003 talks stalled late 2005 resuming in 2007 likely adoption late 2007/early 2008 law by mid-2008 (?)