The Plastic Film Production Problem: How Much Is Too Much?

Plastic is a relatively new material, with the first examples dating back to the late 1800s. Its versatility, lightweight nature, high durability, flexibility, and low production cost have made it one of the most widely used materials of modern times. The global annual production of plastic is more than 350 million tons, with Asia being the largest producer, and China alone accounting for 32% of global production in 2022. The rapid growth of the plastic industry is fueled by cheap shale gas and investments from fossil fuel industries, and it is a significant contributor to climate change and environmental pollution.

Global plastic production has grown from 1.5 million metric tons in 1950 to 359 million metric tons in 2018

Plastic is either ''synthetic'' or 'biobased'. Synthetic plastics are derived from crude oil, natural gas, or coal. Biobased plastics, on the other hand, are derived from renewable products such as carbohydrates, starch, vegetable fats and oils, bacteria, and other biological substances. The vast majority of plastic in use today is synthetic due to the ease of manufacturing methods involved in processing crude oil.

The global production of plastic has grown exponentially since the 1950s. In 1950, the world produced 1.5 million metric tons of plastic. Fast forward to 2018, and the world produced a staggering 359 million metric tons of plastic. This number increased to 400.3 million metric tons in 2022, with China being the largest producer, accounting for 32% of global production in 2022. North America is the second-largest producer of plastic, with a 17% share in 2022.

Plastic is used in a wide variety of products, ranging from packaging to construction, transportation, electrical, and electronic production, agriculture, and the medical sector. Plastic packaging alone accounted for nearly 44% of plastic production in 2021. The versatility of plastic and its ability to displace other materials such as wood, metal, and glass have contributed to its continued growth in production year after year.

Plastic films, in particular, have a wide range of applications. They are typically formed into rolls by roll slitting and are used in modified atmosphere packaging (MAP) for fresh fruits and vegetables, allowing gas permeability. Plastic films are also used in agriculture as a soil surface mulch for field crop production, with different types of plastic films being used depending on the crop.

While plastic has numerous applications, its environmental impact cannot be ignored. Plastic pollution is a critical global issue, with over 90% of the approximately 1 million PET bottles sold every minute ending up in landfills or oceans. The recycling rate of plastics is also very low, with complex recycling processes and the need for specialized infrastructure.

Asia is the largest producer of plastic, with China alone accounting for 32% of global production in 2022

Asia is the largest producer of plastic in the world, with China alone accounting for 32% of global production in 2022. China's plastic production has been growing rapidly, with the country producing between 6 and 12 million metric tons of plastic products each month in recent years. This significant increase in China's plastic production is a result of its manufacturing prowess and ability to produce plastics on a large scale. China's dominance in the plastic production market is not only limited to quantity but also quality. The country has made significant investments in research and development, leading to innovations that have improved the performance and durability of various plastic products.

China's plastic production industry has been growing exponentially in recent years, and this trend is expected to continue in the future. The country's economy is projected to keep expanding over the next decade, making the plastic production industry a promising opportunity for investors. China's position as the world's largest manufacturing economy and exporter of goods has contributed to its dominance in plastic production. The country's production output has been increasing due to the rising demand for consumer goods and packaging materials.

While China has implemented new regulations and policies to reduce plastic waste, its production levels remain high. Some argue that the environmental cost of China's booming economy and high plastic production is too great. The strong linkages between plastics and fossil fuels also contribute to climate change, as plastic production is closely linked to the petrochemical industry. The availability of cheap shale gas and growing investments from fossil fuel industries further fuel the rapid growth of the plastic industry in China and Asia as a whole.

The global plastic production has been increasing year after year, with the total worldwide production surpassing 413 million metric tons in 2023. Plastic has displaced many traditional materials such as wood, stone, horn, bone, leather, paper, metal, glass, and ceramic. The annual levels of mismanaged plastics are expected to almost double from 110 million tons in 2019 to 205 million tons by 2040 if no action is taken. This exponential growth in plastic production, especially in Asia, highlights the urgent need to address the plastic crisis and its impact on the environment.

The plastic industry's growth is fuelled by cheap shale gas and investments from fossil fuel industries

The plastic industry has long been aware of the negative environmental impact of its products, yet it continues to deny responsibility and fight regulation. Despite growing global concern about plastic pollution and commitments from nations, cities, corporations, and civil society organizations to reduce emissions and transition to low-carbon products, the industry is investing billions to expand plastic production. This expansion is fueled by cheap shale gas and investments from fossil fuel industries.

Shale gas discoveries across North America have been described as a "shale gale," bringing excitement to the plastics industry. This boom is expected to create hundreds of thousands of jobs in petrochemicals, resin production, and plastics manufacturing, as well as support jobs in the communities housing the plants. The availability of shale-based natural gas, which can be used to produce ethane and ethylene (key feedstock for plastics), has made this growth possible. Companies like Dow Chemical Co. and Berry Plastics Group Inc. are adding capacity and investing in new technology, expecting to benefit from the shale gas boom.

The fossil fuel industry is also investing heavily in additional plastic production capacity. As the world moves away from oil and gas due to climate change concerns, these companies see plastic as an opportunity to maintain their profits. Almost all plastics are formed from chemicals derived from fossil fuels, and the production, use, and disposal of plastics contribute significantly to climate change. A 2021 analysis predicted that the US plastics industry would be a bigger contributor to climate change than coal-fired power by 2030.

The plastics industry's growth, fueled by cheap shale gas and investments from fossil fuel industries, raises concerns about its long-term viability. As global efforts to reduce fossil fuel consumption and confront climate change accelerate, the plastic industry will be profoundly disrupted. Despite this, investors in the plastics boom assume that inexpensive ethane will remain available and that demand for plastic products will continue to increase. However, small changes in fossil fuel prices or supplies can significantly impact plastic production, and the rapid transition to renewables may affect the profitability of these investments.

The average annual plastic consumption in Western Europe is around 150kg per person, more than twice the global average of 60kg

Plastic is a relatively new invention, with some of the first examples dating back to the late 1800s. However, its low production cost and versatility have made it one of the most widely used materials in the world today. Unfortunately, this widespread use has come at a cost to the environment. Plastic waste is a significant contributor to climate change and pollution, with plastic items and fragments making up nearly 80% of the litter found on European beaches.

The durability of plastics means that discarded items remain in the environment for generations. Most plastic items that are used and thrown away are either recycled, incinerated, or properly stored in waste facilities. However, a portion of this waste is mismanaged and finds its way into the seas and onto land, where it can remain for years. In 2019, about 22 million tonnes of plastic ended up in soils, rivers, and oceans, and this number is only projected to increase.

While bioplastics and biodegradable plastics are being developed and trialled, they are not automatically a more sustainable alternative. Bioplastics require resources for their production and can be sensitive to different climates, meaning they may not biodegrade in all environments. However, when designed with a proper waste stream in mind, bioplastics can be useful for single-use plastic such as biodegradable bottles and packaging films.

Plastic is a large driver of climate change, contributing to global emissions, air and water pollution, and oil spills

Plastic is a significant contributor to climate change, with its production, use, and disposal emitting around 3% of global emissions. As 99% of plastics are made from fossil feedstocks, the extraction, refining, and manufacture of plastics are carbon-intensive activities. The production stage, which involves converting fossil fuels into plastics, accounts for around 90% of these emissions. The remaining 10% comes from the end-of-life stage, which includes the disposal and recycling of plastics.

The life-cycle emissions of plastics, including production and disposal, were estimated at 1.8 billion tonnes by the OECD. With the world emitting around 54.6 billion tonnes of carbon dioxide equivalents (CO2eq), plastics are responsible for a considerable proportion of global emissions. The impact of plastic on climate change is not limited to emissions. Plastic pollution, particularly in oceans, may interfere with the ocean's capacity to absorb and sequester carbon dioxide, further contributing to climate change.

Plastic pollution is a pressing environmental issue, with rapidly increasing production overwhelming the world's ability to manage and dispose of plastic waste properly. Plastic trash ends up in rivers and oceans, threatening biodiversity and ecosystems. Plastic waste breaks down into microplastics, which have been found in drinking water systems, the air, and even human blood, lungs, and feces. The impact of microplastics on human health is an urgent area of study, as scientists strive to understand the potential harm they may cause.

Additionally, plastic contributes to oil spills, which are a primary source of water pollution. Recycled plastic powder (RPP) has been proposed as a solution for oil spill cleanup, offering a cost-effective and eco-friendly approach. RPP can selectively adsorb oil while rejecting water, and its unique production method enhances its efficacy and environmental impact.

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