Advanced and mechanical recycling: How can the industry boost circularity most effectively?

27 Sep 2023 --- As global demand for recyclate increases, so does the need for recycling innovation. With low plastic recycling rates globally, the industry is transforming to improve waste management and establish a circular economy. We discuss with experts whether mechanical or chemical recycling is the way forward. 

Coveris’ closed-loop recycling business ReCover generates high-quality feedstock from plastic packaging waste streams for packaging material production. 

It utilizes internal waste streams and customer waste material to produce high-quality recycled feedstock, able to be re-extruded into a variety of premium-quality films and packaging applications. Material containing recycled content can be recycled through the ReCover processes, enabling a continuous loop of recycling and re-extrusion. 

“Technologies we have invested in mean we are at the forefront of creating sustainable, recycled solutions for the flexible plastics industry and our customers using mechanical recycling capabilities,” Mark Dalby, managing director at Coveris ReCover, tells Packaging Insights. 

Mechanical recycling in the lead
Mechanical recycling has been the main plastic recycling method for over 30 years. It preserves the molecular structure and mechanically crushes plastic, allowing it to be remelted into granulates, which are then used to make new plastic products. 

Mark Dalby, managing director at Coveris ReCover, tells us that the tech allows material to be upcycled into premium packaging content. But Neil Farmer, founder and owner of business development consultancy Neil Farmer Associates, explains that it is not as straightforward in practice. “Analysis by [waste management services expert] Biffa shows that the average contamination rate of mechanically recycling waste in the UK has risen from 13.4% in 2016 to 17% by the end of 2020.” 

“The need is for better separation of materials in the recycling stream, which requires investment in infrastructure,” he says. 

Nevertheless, mechanical recycling has wide acceptance and is the default approach to recycling. “It is most effective with high quality clean sorted waste, hence the need for more investment in infrastructure to achieve more of this,” asserts Farmer.

Compared to other recycling technologies? 
Innova Market Insights data suggests Recyclable is the leading category in environmentally sustainable packaging claims for F&B launches. The market researcher found that recyclable packaging claims experienced a global 7% growth between July 2018-June 2023. 

These claims were applied to products packed in materials like Plastic – Not Specified, Carton and Plastic – PET. Additionally, the utilization of alternate materials for recyclable claims has surged in the last five years. 

Through ReCover’s mechanical recycling processes, there is the ability to upcycle material and utilize this as more premium recycled content for consumer applications. “With the increased focus on sustainability around packaging materials and introduction of various taxes and levies on plastics, our process can provide a suitable, sustainable supply of recycled plastic,” says Dalby.

Growing recyclate demandsPackaging expert Neil Farmer explains mechanical recycling remains to be the default approach to recycling.
With an increased focus on sustainability by design, the demand for recycled content within the plastics markets continues to grow, with customers looking for solutions to provide packaging that is fit for purpose, while focusing on the circular approach to these designs. 

“ReCover is able to provide a fully circular approach to recycled content within a fully recyclable low-density PE film while maintaining performance, mechanical properties and brand requirements,” explains Dalby.

“The growth of the ReCover recycling division at Coveris, means we are investing in further technologies and projects to provide innovative and premium quality recyclable offerings.”

ReCover is a key part of the delivery of the Coveris “No Waste” vision and strategy, asserts Dalby. “It is also perfectly aligned to government sustainability agendas and will assist our UK customers in meeting their obligations for future EPR legislation.”

A future for advanced recycling?
Advanced recycling leads to chemical change, implying a longer route from plastic waste to usable plastics. Farmer says that it is likely that demand for advanced recycling will increase, although demand is very small at present.

“The need to achieve circular economy targets, which are challenging, is likely to lead to a greater commitment to advanced systems,” he explains citing data estimating advanced recycling could grow to between 4-8% of total plastics supply by 2030. However, this would require more than US$40 billion of total investment.

But Farmer is skeptical about the likelihood of advanced recycling achieving these numbers.

“Advanced recycling technologies need improvements in infrastructure. Upscaling and greater critical mass are essential for success,” he elaborates.

“Otherwise, the move away from fossil fuels toward already challenging sustainability targets will not occur at the speed everyone is looking for.”

By Natalie Schwertheim