Menshen harnesses Borealis’ plastics recycling technology for circular closures

30 Sep 2020 --- Borealis and Menshen, a plastic closures and packaging systems specialist, are collaborating on a ten closure series based on Borcycle. Borcycle is an evolving recycling technology that transforms polyolefin-based waste streams into value-adding packaging solutions.

Borcycle is used to manufacture various compounds made of recycled polyolefins (rPO), ideal for sophisticated rigid packaging applications.

The technology unites the Borealis recycling and compounding expertise with its Borstar multi-modal and nucleation technologies.

“PCR (post-consumer recycled) material is generated from household waste and doesn’t undergo a full production process. It is all about sorting, grinding and compounding to achieve the approximate reductions against virgin material,” Simone Hesener, sales manager at Menshen, tells PackagingInsights.

The Borcycle packaging solutions are designed predominantly for laundry and home care applications and include 2K closures.

“These closures come in a natural grey. White or transparent PCR is available but difficult to find in sufficient quantities and qualities,” Hesener continues.

Click to EnlargeBorcycle manufactures various rPO compounds for sophisticated rigid packaging applications.“We worked with different masterbatch producers and now have masterbatches available in various colors that create slightly opaque tones.”

Carbon savings and recyclability
Menshen employs a rigorous process to ensure that the quality of the PCR material selected for a closure is in perfect alignment with its required functionality.

Borealis and Menshen determined that Borcycle UG522MO, a PP compound made of 50 percent PCR content, would be ideal for the new closures.

The compound offers a potential 15 percent reduction in CO2 emissions compared to virgin PP, and end-of-life recyclability in existing PCR streams.

PCR supply hurdles
In July, the European Council approved the implementation of a plastic tax starting January 1, 2021. The plan foresees a €0.80/kg levy on non-recycled plastic packaging waste, paid by Member States into the EU budget.

Hesener explains that 100 percent PCR closures are possible today, but the material is in short supply.

“It all depends on the appropriate quality of the PCR material, which is still not widely available in the quantities needed to ensure that technical specs for certain closures can be met.”

Europe and US availability
The closures are available in Europe and can also be made available in the US.

“Borealis can make the material available relatively quickly. Production can start right away, as all virgin material closure specs can be met [with the PCR solution].”

“Teaming up with Menshen to deliver high-quality closures made of 50 percent recycled PCR is proof positive that innovation and teamwork can move the industry closer to a circular economy,” notes Meta Cigon, marketing manager consumer products at Borealis.

Click to EnlargeHesener explains that 100% PCR closures are possible, but the material is in short supply.“The functionality of a closure may be affected by natural variations in PCR materials. By leveraging our respective areas of expertise, Menshen and Borealis can determine which ratios of recyclate and virgin material are appropriate for which applications,” explains Ulrich Fleischer, head of sustainability at Menshen.

“We are pleased to collaborate with Borealis in fulfilling growing demand among our own customers as well as retailers and end consumers for a broader spectrum of sustainable, yet high-quality packaging options.”

Circular launches
Austrian-headquartered Borealis recently launched the Bornewable portfolio of circular, premium polyolefins. The polyolefins are produced with renewable feedstock derived entirely from waste and residue streams.

The polyolefins can be converted into eco-friendly face masks, essential in the battle against COVID-19.

PCR plastic use is on the rise. Loop Industries and Suez are building the first Infinite Loop recycling facility in Europe. Infinite Loop is an enhanced recycling technology for producing virgin quality, food-grade recycled plastic.

In August, smart multi-packer WaveGrip unveiled a 50 percent recycled plastic carrier for cans that delivers the latest on-pack marketing messages.

By Joshua Poole

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