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Recycling rigid plastic packaging

Plastic, often regarded as an environmental villain, can be an environmental hero, with the right embrace of recycling.

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Rigid plastic packaging (hereafter, plastic packaging) has received ardent criticism in the era of sustainability. After all, it’s made from petroleum and can endure for centuries, whether in landfills, as litter, or as pollution in waterways. Despite that profile, plastic packaging continues to expand its applications, both in variety and in volume. As for the latter, no better example need be cited than the PET water bottle, with its yearly worldwide production in the high billions. It’s understandable that there are those who regard sustainability and plastic packaging as dueling trends. However, the answer to a win-win co-existence resides in recycling.

Which is not to say that recycling is new. To the contrary, it’s one of sustainability’s ‘Three Rs,’ along with Reuse and Reduce. What is new is the continuing growth and development of the infrastructure that supports plastic recycling.

At this juncture, it would be helpful to digress for a few facts. First, packaging is far from being the biggest user of plastic. Yet plastic packaging is singled out disproportionately as an environmental problem. That’s because plastic packaging (as does packaging in general) later becomes a post-consumer disposal issue──in a word, garbage. Its in-your-face presence impossible to ignore. Second, there always have been money-making opportunities in garbage. For example, someone has to haul it. Third, recycling is the alchemy that can turn discarded plastic packaging into profits.

Returning to the topic, the referenced infrastructure is composed of individual households, communities, municipalities, haulers, material recovery facilities, production facilities that use recycled plastic packaging, and consumers of products made from recycled plastic packaging.

That such an infrastructure presently is supported by today’s modest recycling rates bespeaks the astronomical tonnage plastic packaging comprises. It’s estimated that 65% to 70% ends up in landfills. A related estimate is that only 25% of plastic beverage bottles are recycled.

Those rates, nonetheless, have justified capital investments, particularly at material recovery facilities. Not long ago, those facilities were characterized by high levels of manual labor and were barely mechanized beyond conveyors. Now, there are facilities with technological upgrades. For example, sorting is performed using various types of optics that can distinguish among plastics by type and even by color. It’s a capability that reduces the problem of one type of plastic contaminating the stream of another type of plastic.

After undergoing sorting, plastic packaging (such as bottles) is flattened and then compressed into large bales weighing upwards of a thousand pounds, thereby providing efficiencies in handling, storage, and transportation. The more homogenous the bales, the more useful they are for specific downstream operations that are performed by other members of the supply chain.

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