TC Transcontinental Packaging innovates 30% recycled shrink film for Coca-Cola

13 Nov 2020 --- TC Transcontinental Packaging (TC) is incorporating 30 percent post-consumer recycled (PCR) content into its Integritite collation shrink film. Coca-Cola brand AHA Sparkling Water is using Integritite for printed case wraps on select Sam’s and BJ's Club Store shelves this Fall.

Integritite PCR collation shrink film is one of many PCR products in TC’s sustainable portfolio.

The North American supplier created a recycling group in February 2020, vertically integrating plastics recycling in its packaging production chain and ensuring the stable procurement of PCR and post-industrial recycled (PIR) resins.

“We aspire toward a 100 percent recycled content shrink film. Today we are producing up to 70 percent recycled content for case wrap applications and it works really well,” Alex Hayden, senior vice president, R&D, innovation and sustainability at TC, tells PackagingInsights.

“The challenges in reaching 100 percent are all about sourcing the right polymers. There are some specific performance attributes with shrink film, so you cannot stray too far from the ideal or it will not perform properly.”

Most municipalities will not accept flexible films in curbside bins, but Hayden is encouraging consumers to bring the films to widespread store drop-off locations.

“We are working with retailers and CPGs to recycle their plastic waste so we can close the loop. We’re excited by the potential to recycle film back into film.”

Weighing environmental factors
The drive for eco-friendly packaging is taking the beverage sector by storm. While TC and others like Dow and Berry Global brand WaveGrip are working to incorporate recycled plastic into conventional shrink film, other companies are innovating in paper-based replacements.

For example, Graphic Packaging International is currently showcasing KeelClip – a paper-based can multipack carrier that replaces plastic rings – at Pack Expo Connects. In August, Coca-Cola European Partners adopted CanCollar paperboard ring technology for multipack cans in Spain’s Balearic Islands.Coca-Cola brand AHA Sparkling Water is using Integritite for printed case wraps.

Whether to stick with shrink film or adopt paper-based replacements is “the right question to ask and very complex to answer,” says Hayden.

“A lot of attention gets placed on end-of-life versus the cradle-to-grave environmental impact of packaging choices. We use a life cycle analysis (LCA) tool to evaluate all of our sustainable design solutions.”

“You do have to decide how you’re going to weigh different environmental factors, such as greenhouse gas emissions, fossil fuel usage and water usage. Input factors such as shipping methods and distances, energy used in manufacturing, and end-of-life treatments are some of the variables that can significantly alter the outcome.”

“You also have to factor in the weight of the product you’re packaging and the suitability of the plastic or paper-based packaging for use. In the case of shrink film, PCR’s inclusion is a significant improvement in many aspects of the LCA. A light gauge, high recycled content film, which is recycled at end-of-life, is highly desirable from an LCA perspective.”

Imperceptible esthetic differences
The addition of PCR resin has an imperceptible effect on the Integritite film’s esthetics and performance. Hayden explains this is a result of screening a variety of PCR sources and then taking those polymers and their characteristics into account when rebalancing the overall film formulation.

TC also adjusted and validated its processing conditions to cope with some of the imperfections found in PCR polymers.TC created a recycling group in February 2020, vertically integrating plastics recycling in its production chain.

“The typical consumer is not going to notice any difference whatsoever, except the label stating that it contains recycled content,” says Hayden.

“As packaging professionals, however, we can measure some very subtle differences, including haze and tiny film inclusions. You might recall how recycled paper looked in the early days. I think we’ll be on a similar journey with plastics.”

North American recycling drivers
While regulatory changes are being considered, the push to more recycled content in packaging is relying on converters, customers, and retailers reacting to the challenge, explains Hayden.

“This has ratcheted up as consumer perception and media coverage has ramped up over the past years. I truly think everyone is wanting to resolve the issue to reduce the environmental footprint.”

“At TC, we feel a big sense of purpose around how we design and manufacture more sustainable products.”

Consumers will find AHA Sparkling Water’s PCR-incorporated packaging on select Sam’s and BJ's Club Store shelves this Fall in Ohio, Virginia, Maryland, West Virginia, Indiana, South Carolina, North Carolina, Arkansas, Tennessee, Kentucky, Mississippi and Delaware.

“We are proud to support Coca-Cola in sourcing flexible packaging with recycled content to contribute to the establishment of a circular economy for plastics, and to meet our shared Ellen MacArthur Foundation’s New Plastics Economy Global Commitment signatory vision of a future whereby plastic never becomes waste,” concludes Hayden.

By Joshua Poole