Maya Ellison
Plastic-coated paper is a hybrid material that combines paper and plastic. This type of packaging is commonly used for food and beverage products, such as milk and juice cartons, to maintain freshness by blocking out light and air that may cause spoilage. The process of recycling plastic-coated paper can be challenging due to the need to separate the paper and plastic components. While some municipalities have the capacity to recycle these hybrids, many do not, resulting in a significant amount of waste ending up in landfills. To improve the recyclability of plastic-coated paper, some options include making the plastic layer easily removable or transitioning to a coating that can be recycled alongside the paper component.
| Characteristics | Values |
|---|---|
| Recyclability of plastic-coated paper | Plastic-coated paper is not easily recyclable. |
| Plastic coatings | Plastic films are laminated onto paperboard to provide a practical barrier. |
| Recycling process | The plastic coating must be removed from the paperboard to recycle it. |
| Alternative coatings | Water-soluble coatings can be used, which dissolve during the paperboard manufacturing process, making the product fully recyclable. |
| Carton recycling | Cartons are a hybrid of paper and plastic and are not always accepted by municipal recycling programs. |
| Carton composition | Refrigerated cartons contain 80% paper and 20% plastic; aseptic or shelf-stable cartons contain additional aluminium. |
| Carton recyclability | Cartons are recyclable if the plastic layer is removed, leaving behind paper fibres for new products. |
| Local recycling programs | Check local programs to confirm what is recyclable in your area. |
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What You'll Learn
Plastic-coated paper recycling is dependent on the coating type
Plastic-coated paper is any paper that has been coated by a mixture of materials or a polymer to improve qualities such as weight, surface gloss, smoothness, or reduced ink absorbency. The coating can be applied as a solution, molten liquid, or powder, and it can be made from various materials, including plastics, kaolinite, calcium carbonate, bentonite, and talc.
While plastic coatings can improve the function of paper, they usually make recycling more difficult. The recyclability of plastic-coated paper depends on the type of coating and the specific recycling process. Some plastic laminations can be separated from the paper during recycling, allowing the film to be filtered out. Shredding the coated paper before recycling can also help with the separation process. However, the degree of separation still depends on the specific recycling process and equipment used.
Some plastic coatings are water-dispersible or water-soluble, aiding in the recycling and repulping process. For example, a water-soluble coating can be used to provide grease resistance for paperboard used for dry but fatty or oily food. If the used packaging is free from gross contamination with food, the water-soluble coating will dissolve in the paperboard manufacturing process, making the product fully recyclable.
In some cases, special recycling processes are available to help separate plastics from paper. However, some plastic-coated papers are incinerated or landfilled instead of being recycled. Most plastic-coated papers are not suitable for composting, but they may still end up in compost bins, contributing to the global microplastics waste problem.
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Plastic films are laminated onto paperboard
There are two main types of lamination processes used: wet lamination and thermal lamination. In wet lamination, a bonding agent such as wax or a hot melt adhesive is applied in a molten state to one of the substrates, allowing for the production of paper-paper and paper-aluminum foil laminates. This process is commonly used in the packaging of cookies and bakery products. Thermal lamination, on the other hand, involves coating the substrate with an adhesive or resin that has a low melting point, allowing the film to be applied using heat and pressure. This method is often used for book lamination, magazines, diaries, and other printed and unprinted paper products.
The type of lamination film chosen depends on the specific application and requirements. BOPP, nylon, and PET laminating films are the most common types used in the paper and packaging industries. BOPP films, or biaxially oriented polypropylene, offer a wide range of finishes and shades, contributing to the finished product's looks and feel. Nylon films provide excellent anti-static properties and are suitable for high-speed lamination. PET films are versatile and can be used in various applications, from food packaging to containers.
The lamination process can be performed using a roll laminator or a pouch laminator. Roll laminators use two rolls, one on top and one on the bottom, which apply pressure and heat to adhere the film to the substrate. Pouch laminators use a plastic pouch that is sealed on one edge and coated with a heat-activated film. The substrate side of the board also has a heat-activated adhesive, which bonds the print to the substrate as it passes through the laminator. Pouch laminators are more suitable for moderate use, while roll laminators are more efficient for large-volume lamination projects.
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Coatings can be made from many substances, including plastics
Plastics themselves are organic polymers of high molecular weight, which are often mixed with other substances called additives. The word "plastic" comes from the Latin "plasticus" and the Greek "plastikos," both of which mean "capable of moulding." This mouldability is a key characteristic of plastics, allowing them to be formed into a wide range of products.
There are two main types of plastics: synthetic and biobased. Synthetic plastics are derived from crude oil, natural gas, or coal, while biobased plastics come from renewable sources such as carbohydrates, starch, vegetable fats and oils, bacteria, and other biological substances. Despite the growing demand for renewable resources, the majority of plastic in use today is still synthetic due to the ease of manufacturing methods involving crude oil processing.
The process of making plastic involves several steps, including compounding, polymerisation, and moulding. In compounding, different materials are melt-blended to create formulations for plastics. This is followed by polymerisation, where hydrocarbon monomers are linked together by chemical mechanisms to form thick, viscous substances known as resins. These resins are then used to make plastic products through processes like extrusion or moulding.
While plastic coatings can provide various benefits, they can also pose challenges when it comes to recycling. For example, plastic-coated paper may not be recyclable in all locations due to the difficulty of separating the plastic from the paper during the recycling process. Similarly, waste wood containing plastic coatings and other contaminants can inhibit recycling and energy recovery, requiring specialised incineration facilities.
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Plastic layers must be removed from paperboard before recycling
Plastic-coated paperboard is commonly used in packaging like cereal boxes, food boxes, and tissue boxes. The plastic coating provides a practical barrier, preventing moisture from entering or leaving the pack. However, this plastic layer must be removed before recycling the paperboard.
When recycled, the plastic layer needs to be separated from the paperboard to recover the fibres and create new recycled paperboard. This is because plastic films are too thin to be recycled along with the paperboard. While some coatings are made from natural sources or are biodegradable, they still need to provide similar properties as traditional plastic layers, such as water resistance.
There are two main methods of applying plastic coatings to paperboard: lamination and extrusion coating. In lamination, plastic films such as PE and PET are applied to the paperboard, creating a plastic-lined surface. In extrusion coating, molten plastic is applied as a curtain to coat the moving web of paperboard. Regardless of the application method, the plastic must be removed for effective recycling.
To facilitate the recycling process, packaging manufacturers are encouraged to use less than 5% plastic in a single pack. This can be achieved by making the plastic layer easily removable or by transitioning to a "coating" that can be recycled alongside the paperboard. By reducing the amount of plastic in packaging, we can improve the recyclability of paperboard products and reduce our environmental impact.
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Cartons are recyclable but may not be accepted by local programs
Plastic-coated paper is recyclable, but it is not always accepted by local programs. This is because the recycling process is complex and costly, and not all materials are profitable to recycle.
When a batch of recycling is heavily contaminated with non-recyclable items, it may be too dangerous or expensive to sort, and so it must be sold for a lower price. This means that some local programs will not accept certain materials, even if they are technically recyclable.
It is important to check with your local recycling program to learn which items they accept. For example, some programs do not accept plastic bags or plastic wrap/film, and these must be recycled at specific locations, such as retail and grocery stores.
Some materials, like glass, are widely accepted by most municipalities, but broken glass is not safe for workers to handle and can damage equipment, so it is not accepted. Similarly, some materials are considered household hazardous waste (HHW) and require special care when being disposed of. This includes items like pesticides, paints, batteries, and aerosols, which can be dangerous for people and the environment if not disposed of correctly.
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Frequently asked questions
Plastic-coated paper is any paper that has a layer of plastic applied to it to provide a practical barrier, for example, to stop moisture from entering or leaving a package.
Plastic-coated paper can be difficult to recycle because the plastic layer needs to be removed from the paper to allow the fibres to be recovered and used to make more recycled paper. You can check locally to see if you can recycle plastic-coated paper by visiting the Carton Council or Earth911 Recycling Search.
Examples of plastic-coated paper include milk and juice cartons, ice cream cartons, and takeout cartons.
