Alpla’s recycled HDPE delivers huge carbon savings against virgin material in new analysis

10 May 2022 --- Alpla’s Spanish recycling plants are reporting that their recycled HDPE (rHDPE) generates 88% fewer carbon equivalent emissions than virgin material. The finding comes from an analysis by the independent business consultancy c7-consult. 

The plastic packaging provider extended its recycling operations into HDPE in 2019 when it purchased recycling plants in Suminco in Montcada i Reixac and Venta de Baños.

“The saving of up to 88% CO2 with rHDPE in comparison to virgin material confirms once again that our investments in our global recycling activities are worth it. We wish to continue on this path in the future too,” comments Günther Lehner, Alpla’s chairman.

The company is long-established as a partner for PET recycling with its own plants. A landmark 2017 Alpla study found recycled PET produces 79% lower CO2 emissions than virgin PET.

Climate support
The rHDPE produced in Montcada generated a carbon footprint of 0.24 kg of carbon equivalents per kilogram. This level equates to 88% fewer greenhouse gas emissions than virgin HDPE, which has a footprint of 1.92 kg of carbon equivalents per kilogram.

The rHDPE produced in Venta de Baños likewise has an excellent footprint of 0.28 kg of carbon equivalents per kilogram, putting it 85% lower than virgin HDPE.Alpla’s Spanish plants produce around 25,000 tons of rHDPE each year.

The analysis covers the separate collection and sorting of post-consumer HDPE bottles (primarily in Spain), their shipment to the Alpla recycling plants, and their washing and processing into rHDPE pellets.

The two plants currently have an annual capacity of approximately 25,000 tons of rHDPE.

Color sorting benefits
Alpla focuses on color sorting for recycling HDPE to maintain high-quality color streams and keeps packaging in the loop for a longer time. Turning yellow HDPE into yellow rHDPE, white into white, red into red or blue into blue, for example, reduces the use of color pigments while preventing commingling and “greying” of the material.

The process enables the company to meet many of its customers’ marketing requirements and produce colored packaging using recycled materials. It also supports important measures in the area of design for recycling, which aim to accommodate the complete recyclability of a product at the concept development stage.

Alpla against waste
In 2018, Alpla signed the Ellen MacArthur Foundation’s New Plastics Economy Global Commitment, pledging to spend €50 million (US$52.8 million) to expand its recycling activities up to 2025.Alpla has set aside an average of €50M a year for recycling.

The company has since significantly increased this investment target. From 2021, an average of €50 million (US$52.8 million) a year will be ring-fenced specifically for recycling. In addition, all packaging solutions are to be fully recyclable by 2025, and the proportion of processed post-consumer recycled materials is to rise to 25% of total material usage by this time.

It recently expanded its PET recycling capacity in Germany by acquiring Texplast, and Alpla spearheaded a Romanian PET recycling facility.

Last week, it showcased a new returnable PET bottle together with Vöslauer, an Austrian mineral water company. The bottle reduces carbon emissions by around 30% and bottle weight by 90% compared to reusable glass bottles.

Alpla has also supported recycling infrastructure development in Nepal, and formed a joint venture with global engineered materials supplier Glatfelter and Swedish startup Blue Ocean Closures to develop fiber-based closures using “dryforming” technology.

By Joshua Poole