Project Plastic Fix: UFlex joint president talks circularizing multi-layered flexible plastic packs

22 Dec 2022 --- Flexible plastic packaging is notoriously difficult to recycle, and few countries have real systematic solutions for circularizing these materials. However, flexible plastic remains crucial to preserving food shelf life and preventing the greenhouse gas emissions that result from spoilage. 

PackagingInsights sits down with Jeevaraj Pillai, joint president of new product development and flexible packaging at Uflex, about the company’s recent presentation to the Alliance to End Plastic Waste (AEPW), about how its R&D can provide answers to the circularity pitfalls seen worldwide. 

“Our chairman and managing director, Ashok Chaturvedi, shared his experience and best practices from the UFlex group in recycling multi-layered mixed plastic waste (MLP) with the attendees at the AEPW board meeting in New York, US. The presentation included a virtual walkthrough of the UFlex recycling facilities in India, Poland and Mexico,” Pillai explains.

“As one of the largest flexible packaging players globally, we are cognizant of our responsibility and have led by example by putting post-consumer plastic to better use.”

“We are constantly creating a robust portfolio of innovative and sustainable offerings, where material is sourced responsibly; products can be recycled or find second life post consumption.” 

Collection and sortation are some of the key issues facing flexible plastic circularity, according to Cflex.Overcoming recycling challenges 
Pillai explains Uflex endeavors to share its expertise in recycling multi-layer mixed plastic waste with the rest of the world and “to encourage central and state governments, policymakers, non-profit organizations and consumer groups to create the right plastic waste management ecosystem and invest in conducive policies and supporting infrastructure.” 

“In India, we have been working closely with the central and local state agencies to replicate recycling projects in other Indian cities,” he says. 

“We hope that the presentation and the subsequent media outreach will help create a collaborative platform for companies, legislators, civic authorities and entrepreneurs to work toward recycling and upcycling plastic waste across global regions.” 

Essential policy aid
While UFlex is one of the leading global players in flexible packaging, private enterprises cannot solve the circularity problem without governmental help, asserts Pillai. 

“We take our responsibility toward building and contributing to a plastic circular economy seriously. Having said that, systemic changes in consumer behaviors, investments by central and state government bodies toward building the right waste management ecosystem and incentives for entrepreneurs and all related parties to work toward a shared vision is a concerted effort and requires several stakeholders to work together.” 

“We will continue to raise awareness about recycling, play the role of a facilitator in these strategic alliances and discussions, and make progress on our sustainable journey,” he continues. 

“Reiterating our chairman’s commitment from the AEPW board meeting, we would be happy to lend our technical expertise and know-how to any interested party that would like to replicate and scale the recycling efforts in their community or organization.”

Monomaterial problems 
Advanced recycling has faced criticism recently following studies showing pyrolysis is highly energy intensive.Monomaterial designs and refills are viable options for a few packaging needs, but by “no means” are they a feasible substitute for flexible packaging in its entirety, asserts Pillai.

“The monopolymer packaging materials mostly being considered are based on either PP or PE. The following issues make them far-fetched in their implementation: 

• The properties of the hetero-polymer packaging laminate used today are hard to achieve through mono-polymer options.
• The raw material for mono-polymer packaging materials is expensive.
• It is not possible to up-cycle the mono-polymer material by mechanical recycling. Hence it will follow the same fate as that of hetero-polymer packaging material without adding any value.
• Monopolymer packaging is proposed to be upcycled by chemical recycling to convert into monomers to create circularity. The infrastructure for chemical recycling has yet to be made readily available.
• They are expensive. The incremental cost prevents this from being used for packaging the low-price point end-products

Advanced recycling issues?
Recently, various studies have shown that the use of advanced recycling technologies such as pyrolysis is hugely energy intensive – leading critics to dismiss proponents for “greenwashing” and call on policymakers to prioritize mechanical recycling and require the industry to revert to monomaterial designs.

However, Pillai says Uflex is “not aware of any such criticism.” He says, “the biggest challenge we face is collecting and sorting plastic waste, especially MLP.” 

“It would be simple if we could get PCR from a materials recovery facility or any other municipal body. We have a complete recycling solution for mixed plastic waste and supply or access to this waste is the biggest challenge.” 

By Louis Gore-Langton