Nextloopp, Tomra and MCC Verstraete trial adhesive-free fluorescent markers for PP recycling

26 Jun 2023 --- Nextloopp, Tomra and MCC Verstraete have successfully trialed adhesive-free and fully printed PP label wrapping dubbed NextCycle IML for removing ink residues from in mold labeling (IML) surfaces, which have previously been problematic in food-grade recycled plastics.

Following recent trials undertaken at Tomra as part of Nextloopp’s lead-up to demonstrate its PolyPPRISM sorting technology at commercial scale, the team trialed their fluorescent markers on Belgium-based MCC Verstraete’s IMLs. 

PolyPPRISM is a technology that sorts packaging using luminescent materials encoded on labels or sleeves. 

The trials, which resulted in 100% purity and 100% yield during internal tests, propel the multi-participant project a step closer to their goal of producing high-quality recycled food-grade PP (FGrPP). 

“What makes it special is that following trials in conjunction with MCC Verstraete and Tomra, Nextloopp can demonstrate a solution that will satisfy both brand owners’ and recyclers’ requirements of having a fully decorated pack that yields an unpigmented PP resin,” professor Edward Kosior, founder of Nextek and Nextloopp, tells Packaging Insights. 

For the trials, circularity technology company Tomra’s autosort unit, Flying Beam, with integrated UV illumination was used. Direct spectophotometric measurements analyzed the strength of the fluorescence emissions to ensure that there was sufficient fluorescent signal to provide the highly-effective sorting of food-grade labeled packs. 

The trials bring the project closer to producing high-quality recycled food-grade PP.NextCycle IML
Having established successful sorting rates, Nextloopp is working with MCC Verstraete to showcase NextCycle IML, a new generation of in mold labels that features automatic detachment and removal during conventional recycling processes. 

NextCycle IML consists of an adhesive-free, fully printed (with non-bleeding inks) PP label wrapped-around a PP tub that is separated from the containers at the grinding and air elutriation stages. 

“This step provides a positive step in removing ink residues from the IML surfaces that have previously been problematic in food-grade recycled plastics,” says Kosior. 

Through the technology, brands can have fully decorated IML containers that are used over natural PP substrates to provide a separate stream of natural PP-free from print and label residues.

Further trials are to follow on Nextloopp participant branded products to demonstrate the viability of using new generation decorative technology designed for PP packaging that can be effectively sorted and decontaminated back to food-grade resins. 

Sorting food-grade labeled packs
Kosior explains that the main challenge for effective sorting of food grade packs would be to have the wide range of brand owners and converters adopt a universal system for separating food-grade from non-food grade packages. 

“The preparation of the labels is very straightforward as it involves the use of conventional printing of labels and sleeves. The sorting centers would require an upgrade of a UV light source and a software upgrade to identify the codes on the packaging. Once these two items are addressed the separation from food and non-food packaging can be achieved at full sorting speeds.”

“Brand owners and packaging converters need to make the commitment to creating a circular destination for their packaging so that the materials can stay in the loop for their products rather than being downgraded into non-packaging applications. This is the biggest and simplest step as the technology is highly developed and effective,” he says. The trials bring the project closer to producing high-quality recycled food-grade PP.

Tomra in Scandinavia 
Earlier this month, Tomra announced it is collaborating with the municipality of Aarhus, Denmark, to establish a deposit return system (DRS) for takeaway packaging in the city center. 

The collaboration agreement for a three-year trial will initially focus on takeaway cups with a deposit. The plan is to expand the system to cover all types of takeaway packaging, ensuring a holistic, convenient and sustainable system.

Meanwhile, Tomra and Plastretur collaborated for a €50 million (US$53.8 million) joint venture to create Norway’s first dedicated sorting plant accepting municipal-sourced separated and mechanically recovered mixed plastic waste. The plastics will be sorted into seven types and processed into high-quality fractions to produce new packaging and other high-quality products.

“We aim to lessen the dependence on fossil fuels. For Norway to achieve the objectives of the [EU] packaging regulation on the content of recycled plastic in packaging while contributing to the ambitions of an increased recycling industry in Norway and shorter transports of waste, it is a fundamental prerequisite that we make a greater effort for the collection and sorting of plastic packaging for recycling,” Joachim Amland, senior vice president at Tomra Feedstock, told Packaging Insights.

By Natalie Schwertheim