Recycling flexible packaging test delivers promising future

As a pilot research report by the MRFF demonstrates, the successful collection, separation and preparation for recycling of flexible plastic packaging (FPP) is possible. This is a replicable model which other communities can adopt.

The pilot project was performed with J.P. Mascaro & Sons at their TotalRecycle Material Recovery Facility (MRF). It demonstrates that with adequate blowers and optical sorting capacity, flexible packaging can be efficiently captured in a single-stream MRF and converted to a commodity bale that can be readily reused in a variety of markets while diverting waste from landfills and the environment.

As part of Amcor’s commitment to partnering with businesses and communities to promote recycling, the company contributed to grants for the installation of state-of-the-art sorting equipment at the J.P. Mascaro TotalRecycle MRF. Additionally, Amcor’s North America Sustainability Director Fabio Peyer participated in the end-market search for outlets to receive reclaimed FPP. Amcor is a seated member of the MRFF Steering Committee, which oversaw the pilot, supported strategic decision making and is now working toward the next steps in the scaled expansion of the project to other regions.

FPP an important part of consumers' life

FPP is one of the fastest growing consumer packaging formats. Its lighter weight and durable strength profile protects food which otherwise could become waste. With more than 12 billion pounds of FPP entering the U.S. marketplace each year, it is an important part of the daily lives of consumers. At the same time, we’re faced with the critical challenge of addressing its environmental impact and developing ways to recover and reuse these materials.

The MRFF pilot aimed to do precisely that, by demonstrating that a large, high-speed MRF could successfully sort flexible plastics as part of the single-stream (think curbside pick-up) residential collection process, turning it into a commodity bale (also known as rFlex) fit for reprocessing into recycled content.

Birdsboro pilot a significant project

The Birdsboro pilot is significant because its purpose was to add FPP to the items that consumers can return to recycle bins for processing as part of the regular recycling stream. Currently, recyclable FPP is typically returned to in-store recycling locations.

If you haven't visited an MRFs, they’re a critical component of residential and commercial recycling programs. These are the facilities that receive recyclable waste left at curbsides and in receptacles by consumers and businesses. MRFs use a combination of equipment – and labor – to separate and bale materials in preparation for shipment to a downstream recycler.

When it comes to MRF output, a successful rFlex bale needs to consist of at least 60 percent of single-resin polyethylene films and laminates. This includes items like grocery, bread bags and product overwrap.

In addition, a successful bale should include only up to eight percent multi-material films, bags, pouches and other laminates where the predominant material consists of polyethylene and limited contaminants. This includes no more than two percent polyethylene terephthalate (PET), one percent polyvinyl chloride (PVC), one percent metal foil, one percent nylon, less than seven percent single-resin polypropylene films and laminates, and no more than 15 percent paper contamination.

Study demonstrates FPP recycling can work

The pilot study set out to achieve five goals: 1) Capture at least 90 percent of the FPP, 2) Minimize paper in the FPP (rFlex) bales, 3) Reduce the amount of FPP going into fiber products, 4) Reduce fiber quality control staff by 25 percent and reallocate that staff to other MRF job functions, and 5) Integrate FPP recovery systems into the existing MRF control system.

The pilot culminated with a report covering three elements of the recycling system: processing, community collection and end-markets.

Processing measured the performance of the recycling operation and the quality of the rFlex bales to measure how effectively the FPP was being captured. Community collection monitored and tracked the impact of adding FPP to curbside collection programs documenting progress and developing new practices for introducing the materials into existing programs. And finally, the end-markets workstream investigated regional, North American and international technologies capable of processing rFlex bales.

The study reached a promising 74% level on its first goal and accomplished all the remaining four. Process changes have continued to improve capture rates. These changes, along with the introduction of quality control at the beginning of the sorting process, have led to confidence that the capture of 90 percent of FPP is achievable.