Dow launches recycled polyethylene resin in North American shrink film circularity boost

05 Nov 2020 --- Dow is launching its first post-consumer recycled (PCR)-rich resin for collation shrink film in North America, enabling companies to incorporate more post-consumer materials while maintaining application performance.

The recycled plastic resin is designed specifically for retail and logistic shrink film applications and expands Dow’s circular technology portfolio by offering shrink film with up to 40 percent PCR content.

The recycled material in Dow’s XUS60030.01 Experimental Low-Density Polyethylene Resin includes 70 percent certified film-based PCR.

CO2 and energy reductions
The resin can help companies reduce their carbon dioxide emissions and energy footprints significantly by using a high percentage of recycled plastics.

“One kT of formulated recycled resin for shrink wrap is estimated to provide greenhouse gas emissions savings equivalent to over 1.5 million miles driven by the average passenger vehicle and energy savings equivalent to the electricity used in 370 US households in one year,” Victor Zapata, Dow’s recycling commercial director for North America and Latin America, tells PackagingInsights.

One kT of shrink wrap recycled resin can save the energy equivalent of electricity used in 370 US households in one year.The resin offers flexibility to customize PCR content for shrink applications recyclable as all-polyethylene films.

Aesthetics and performance
Dow’s developmental objective for PCR incorporation into its formulations is to focus on improving quality and consistency in the final product to yield films with performance and processability similar to films made with virgin material, describes Zapata.

“As with any new application, extensive product testing is needed to make sure it meets Dow’s rigorous standards, and we’re performing external trials with target customers to validate and optimize final film formulations.”

Dow confirms a package containing 40 percent PCR content delivers application performance comparable to a virgin film formulation while also maintaining good aesthetics.

“There is an increase in haze, and gels and contamination will be visible when compared to virgin film. However, when using Dow’s PCR-rich product, the haze, gels and contamination are reduced versus dry blending film-based PCR,” explains Zapata.

High-quality PCR supply
In January 2020, Dow announced a PCR film pellets supply deal with Avangard Innovative. Since securing this “reliable, quality supply of PCR,” Dow is evaluating new linear low-density polyethylene (LLDPE) and low-density polyethylene (LDPE) PCR products.The PCR resin can produce shrink applications recyclable as all-PE films.

“In June 2020, Dow announced new sustainability targets focused on eliminating plastic waste by increasing global recycling and designing products for recyclability,” continues Zapata.

“The launch of our PCR-rich resin is aligned with Dow’s strategy of designing products for circularity and implementing recycling solutions to provide new life for used plastics.”

Dow is developing additional PCR innovations for various applications in industrial and consumer packaging markets in 2021. Dow is hosting a webinar on November 9, 2020, to reveal more about the new PCR-rich resin for shrink film.

Environmentally-focused films
Eco-centric film innovation is gathering pace with more stringent circularity legislation, like the EU Plastics Tax, on the horizon.

Berry Global brand WaveGrip is unveiling a new carrier design for cans, containing over 50 percent recycled plastic. WaveGrip is recyclable with PE film collection schemes and weighs less than 4 g on a standard six-pack.Dow confirms film containing 40% PCR delivers performance comparable to virgin film while maintaining good aesthetics.

Sabic is instigating a pilot project with Schwarz multinational retail group using transparent vegetable film bags made from 100 percent certified circular PE.

Italian packaging provider AMB is bringing easily-recyclable mono-PET high barrier film solutions to European meat producers as part of an “all-in-one” packaging service.

On the compostability front, major bioplastics players BASF and Novamont both launched compostable cling films, tackling plastic pollution and food waste simultaneously.

BASF’s certified compostable ecovio material and Novamont’s Mater-Bi material replace hard-to-recycle conventional plastics like PE while increasing product shelf life.

Similarly, Danimer Scientific and PSI partnered to create home-compostable films containing Danimer Scientific’s proprietary biopolymer, Nodax polyhydroxyalkanoate (PHA).

By Joshua Poole