The Automotive Industry's Plastic Recycling Efforts And Achievements

Plastic is everywhere, from everyday items like bags and bottles to car parts and building materials. However, the reality of plastic recycling is disappointing. While recycling is essential for reducing environmental harm, enhancing gender equality, and supporting local economies, the process is complex, and many items cannot be recycled. Even when plastic is easy to recycle, most of it is not, with only 5-10% of plastic waste being recycled globally. In the context of car manufacturing, the European Commission is currently defining concrete reuse percentages for plastics in cars, with ambitious plans to have 25% (52 kg) of plastics in new cars sourced from recycled materials by 2030.

Plastic recycling targets for car manufacturers

The amount of recycled plastic that goes into a car varies, but currently, even the most progressive car manufacturers only achieve 20% recycled plastic content in their cars, with most achieving well below that (sometimes as low as 8%). The European Commission is working to define concrete reuse percentages for plastics in cars, with ambitious plans in place to ensure that by 2030, 25% (52 kg) of the plastics in a new car must be sourced from recycling, increasing to 30% (62.4 kg) by 2035. These targets present a significant challenge to the automotive industry, which needs to ramp up its use of recycled materials dramatically.

To meet these targets, car manufacturers can employ several strategies and innovative technologies. One approach is to collaborate with specialist recycling companies that can help incorporate more recycled plastic into their manufacturing processes. For example, US-based "materials innovator" Eastman has developed molecular recycling technologies, Carbon Renewal Technology (CRT), and Polyester Renewal Technology (PRT). These processes can break down hard-to-recycle automotive plastics into molecular building blocks, from which new plastics can be produced. CRT has the advantage of being suitable for a broader array of materials and has already been piloted in the US in collaboration with car manufacturers Stellantis, Ford, and General Motors.

Another strategy is to participate in research consortia focused on closing the automotive plastics loop. For instance, the LIFE PlasPLUS project in Belgium involves a consortium led by Comet Traitements, including car manufacturer Stellantis and the University of Liège. This project aims to achieve a high-quality, clean stream of recycled thermoplastics (ABS, PS, and FPP) by recovering Substances of Very High Concern (SVHCs), such as antimony and bromide. This approach not only reduces plastic waste but also ensures that toxic substances are properly managed.

While these initiatives are promising, it is essential to acknowledge the broader challenges in plastic recycling. Currently, less than 10% of the world's plastic waste is recycled, with the majority ending up in landfills and the oceans. This low recycling rate is partly due to the complexity and cost of collecting and sorting plastic waste, the presence of hard-to-recycle plastics, and the expansion of the virgin plastic market. Additionally, some plastic products are designed to be single-use and difficult to recycle, hindering recycling efforts.

To achieve their plastic recycling targets, car manufacturers should advocate for industry-wide change, support innovative recycling technologies, and collaborate with specialists in plastic recycling and waste management. By embracing circular economy principles and working towards the European Commission's targets, car manufacturers can play a pivotal role in reducing plastic waste and promoting sustainability within the automotive industry.

Plastic recycling innovations and technologies

Chemical Recycling

Chemical recycling involves breaking down plastic waste into its molecular components through processes like depolymerisation, pyrolysis, and gasification. Depolymerisation breaks plastic polymers into monomer units, which can produce new plastic products. Pyrolysis and gasification heat plastics without oxygen, converting them into fuel or feedstock for energy production and chemical manufacturing. Pyrolysis also enables the creation of synthetic fuel products, including artificial diesel, gasoline, and aviation fuel, from non-recyclable plastics. Plasma pyrolysis, an advanced version of pyrolysis, employs high-temperature plasma torches to transform plastic waste into synthetic gas, creating energy or chemical products.

Advanced Sorting Techniques and Plastic Conversion Technologies

Innovative recycling facilities employ advanced sorting techniques and plastic conversion technologies to optimise the recycling process. Machine learning and computer vision elements in sorting systems improve accuracy and speed in separating different plastic types.

3D Printing

3D printing with plastic filament made from recycled plastics enables customisable and sustainable designs, reducing the demand for new raw materials. It offers an environmentally friendly alternative to traditional manufacturing processes and highlights the creative potential of recycling.

PureCycle Technology

PureCycle Technology, founded by John Layman, has developed a process to remove colour, odour, and contaminants from polypropylene plastic waste, transforming it into a "virgin-like" resin. As polypropylene is the second-most used plastic globally, with only 1% currently recycled, this technology presents a significant advancement in recycling capabilities.

Plastic Roads

Plastic roads incorporate recycled plastic waste into the asphalt mix, reducing the need for virgin materials and extending pavement lifespan. They provide a more durable, flexible, and crack-resistant road surface while reducing the carbon footprint of road infrastructure.

These innovations in plastic recycling demonstrate the potential for a more sustainable future, reducing plastic waste and promoting circular economy principles.

Plastic recycling rates and statistics

Plastic is a significant component of municipal solid waste (MSW), particularly in the containers and packaging category, which includes bags, sacks, wraps, bottles, jars, and other containers. In 2018, this category accounted for over 14.5 million tons of plastic in the US. The recycling rate for PET bottles and jars was 29.1% in 2018, while the rate for HDPE natural bottles was slightly higher at 29.3%. However, the overall recycling rate for plastic containers and packaging is much lower, with the US EPA reporting an 8.7% recycling rate for all plastics in 2018. This translates to approximately three million tons of recycled plastic out of the total MSW landfilled, which was 27 million tons of plastic.

The recycling rates vary across different regions and cities. For instance, Salt Lake City claims a 99% recycling rate for the plastics it collects, while other sources indicate a 5-6% recycling rate for post-consumer plastic waste in the US in 2021. Additionally, there is a discrepancy between the plastic put into recycling bins and the amount that is actually recycled. While some sources claim that the majority of plastic placed in recycling bins is recycled, others, like a Greenpeace report, suggest that almost none of it is recycled, with most plastic ending up in landfills. This discrepancy may be due to the challenges posed by plastic recycling, as some plastics are difficult or impossible to recycle, and the process can be costly and energy-intensive.

To address these challenges, innovations in plastic recycling technology are being explored. For example, molecular recycling, such as Carbon Renewal Technology (CRT) and Polyester Renewal Technology (PRT), can break down hard-to-recycle plastics into molecular building blocks, creating a more sustainable cycle. These technologies aim to reduce the environmental impact of plastic waste and improve recycling rates.

Plastic waste management and environmental impact

Plastic waste management refers to the processes involved in dealing with plastic products and waste, and it is a critical issue due to the significant environmental and health hazards posed by plastic. The disposal of plastic waste can lead to groundwater contamination, soil degradation, and threats to marine ecosystems, with knock-on effects on human health and ecological balance.

The consumption of plastic products is widespread, and with inadequate waste management systems in place, plastic waste is often not recycled or disposed of properly. This results in plastic ending up in landfills, where it can take hundreds or even thousands of years to degrade naturally. Furthermore, the chemical structure of plastic means that it can release toxic substances as it degrades, leading to nervous system damage, genetic changes, metabolic disorders, and even cancer in humans.

The challenges of plastic waste management are multifaceted. Firstly, there is a rapid increase in plastic production and consumption, with predictions indicating a possible exceedance of 650 million tons of plastic production by 2050, a massive increase compared to 1950. This surge in production is coupled with a low recycling rate, as highlighted by a Greenpeace report which found that most plastic ends up in landfills. While some initiatives, like the one in Salt Lake City, claim to recycle up to 99% of the plastic they collect, the overall recycling rate of plastic is low, with some sources indicating that only 5% to 9% of plastics are recycled. This is due in part to the variety of plastic types, the cost of collection and sorting, and the lack of infrastructure and technical skills for effective hazardous waste management.

To address these challenges, a range of strategies are being explored. These include waste-to-energy conversion techniques, which can minimise waste and create value-added products, and the use of alternative materials such as bio-plastics, glass, paper, and ceramics. Additionally, innovations in recycling technologies, such as molecular recycling, show promise in breaking down hard-to-recycle plastics for reuse. For instance, Carbon Renewal Technology (CRT) and Polyester Renewal Technology (PRT) are being developed to recycle automotive plastics. These technologies aim to create a closed-loop system for automotive plastics, reducing the environmental impact of plastic waste and decreasing greenhouse gas emissions.

Plastic recycling initiatives and their benefits

Plastic recycling initiatives are being undertaken by governments, communities, and organizations worldwide to address the growing problem of plastic waste and its negative impact on the environment. These initiatives aim to reduce, reuse, and recycle plastics, with an increasing focus on sustainable practices and circular economy models.

Government Initiatives:

Several governments have implemented policies and regulations to reduce plastic waste and promote recycling. The European Union (EU) announced a strategy in 2018 to ban single-use plastics, create a comprehensive reuse system, and establish a market for recycled plastics, aiming for a circular economy. The EU's 27 member countries have plastic recycling rates three times higher than the United States. In 2021, Costa Rica banned the importation and distribution of polystyrene, and Maine became the first US state to ban food containers made of polystyrene. Other US states are considering similar measures.

Community Initiatives:

Communities are also taking action to manage plastic pollution locally. For example, Resource Recovery Stations have been established in Australia and Southeast Asia to turn plastic into sellable recyclable material, providing economic, environmental, and societal benefits. In Kenya, Ocean Sole is addressing the issue of discarded thongs on beaches by turning them into artworks, creating economic opportunities and cleaner beaches for turtles to nest.

Organizational Initiatives:

Organizations are developing more recyclable plastic materials and committing to 100% recyclable packaging. They are also investing in new recycling technologies, such as chemical and mechanical methods, to convert plastic waste into useful products. For instance, Eastman is working on molecular recycling innovations like Carbon Renewal Technology (CRT) and Polyester Renewal Technology (PRT) to break down hard-to-recycle automotive plastics for reuse.

The demand for plastic recycling is increasing, and various organizations are working towards a circular economy for plastics. The Plastics Circle, for instance, has created an app to connect businesses with post-consumer recycled (PCR) plastic, ensuring plastic is reused instead of ending up in landfills or oceans.

While challenges remain, such as low recycling rates and the complexity of recycling certain plastics, these initiatives demonstrate a growing commitment to addressing plastic waste and promoting sustainability.

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