Sourcing Recycled Plastic: A Guide To Environmentally-Friendly Procurement

Sourcing recycled plastic is a complex process that requires careful consideration of various factors. The demand for recycled materials is high, but the supply is limited due to the low rate of plastic recycling globally. Brands must work closely with suppliers to establish a steady source of high-quality post-consumer recycled plastic. This involves evaluating the supplier's sources, supply chain, and quality control measures to ensure the material meets the required specifications. Several platforms and initiatives, such as Oceanworks and Precious Plastic, aim to facilitate the use of recycled plastic by providing resources, technologies, and support to brands and individuals looking to reduce their plastic footprint. Additionally, new methods like chemical recycling and distributed recycling with additive manufacturing (DRAM) offer innovative ways to recycle plastic and create new products, contributing to a more sustainable future.

Understand the different sources of recycled plastic and their characteristics

The sources of recycled plastic can be broadly categorized into post-consumer and post-industrial sources. Post-consumer recycled plastic (PCR) is derived from products that have completed their useful life and have been used by consumers, such as PET bottles and jars, or HDPE natural bottles. Post-industrial recycled plastic, also known as post-industrial resin (PIR), is generated during the manufacturing process, for example, scrap materials or excess plastics.

When sourcing recycled plastic, it is essential to consider the specific characteristics of the material and how they align with your intended use. Some key attributes to evaluate include:

• Rigidity and durability: Recycled plastics can vary in their rigidity and durability, depending on the source and previous applications.
• Color safety and colorfastness: The color of recycled plastic can vary, and it is important to ensure that the material is color-safe and will not leech dye into your product.
• Thermal stability: Different sources of recycled plastic may have varying thermal stability, which is crucial to consider if your manufacturing process involves heat.
• Resilience and density: The resilience and density of recycled plastic can impact its performance in your manufacturing process and the final product's characteristics.
• Leaching: Studies have found that most plastics leach hormone-like chemicals. It is important to understand the potential contaminants in the recycled plastic and their impact on your product.
• Compatibility with manufacturing processes: Sourcing recycled plastic that is compatible with your manufacturing process, such as injection molding or blow molding, is crucial for a seamless production flow.
• Recyclability: Consider whether the recycled plastic you are sourcing can be further recycled. Additives or colorants might make plastic more difficult to reuse.

To ensure a steady supply of high-quality recycled plastic, it is recommended to establish partnerships with suppliers and engage in initiatives that promote plastic recycling. This collaborative approach can help address the challenge of limited supply due to low consumer recycling rates and geographical variations in regulations.

Assess the recyclability of the plastic and potential for reuse

When assessing the recyclability of plastic and its potential for reuse, several key factors must be considered. Firstly, it is essential to determine the source of the recycled plastic. This includes establishing whether the materials are from post-consumer or post-industrial sources, as this can impact the quality and suitability of the plastic for specific applications.

The next step is to evaluate the physical characteristics of the plastic. This encompasses assessing its durability, colorfastness, rigidity, thermal stability, resilience, density, and, of course, recyclability. It is crucial to determine if the plastic is easily recyclable and if it can be recycled further. Certain additives, such as colourants, can sometimes make plastic much more difficult to reuse. Additionally, one should consider if the plastic will leech any chemicals into the product, which could be harmful.

The design of the plastic packaging is also a critical factor. The APR Design® Guide, created by the Association of Plastic Recyclers, provides extensive guidance on creating recyclable packaging. It enables users to assess each design feature of a package to ensure compatibility with the recycling process. By following this guide, companies can improve the recyclability of their packaging and increase the yield of high-quality post-consumer resin (PCR), which is beneficial for a healthy recycling system.

Furthermore, when assessing the potential for reuse, it is essential to consider the supply chain and logistics. This includes evaluating the location of the recycled plastic vendor and their ability to meet transportation cost and speed requirements. Additionally, one should consider the market value of the recycled resin and whether it is supported by any legislatively mandated programs.

Lastly, while reuse has the potential for significant environmental and economic benefits, it is important to acknowledge the challenges and skepticism surrounding it. The success of reuse initiatives depends on various parameters, such as transportation methods, distances travelled, and the number of reuse rotations. Therefore, a comprehensive understanding of the supply chain and potential reuse models is vital when assessing the potential for reuse.

Evaluate the supply chain and logistics considerations

Evaluating the supply chain and logistics considerations is a critical aspect of sourcing recycled plastic. Here are some detailed instructions and considerations to keep in mind:

Understanding the Supply Chain

Firstly, it is essential to comprehend the intricacies of the recycled plastic supply chain. This involves knowing the sources of the recycled plastic, which can be post-consumer or post-industrial. Post-consumer recycled plastic comes from the recycling of plastic products by consumers, while post-industrial plastic is recycled during the manufacturing process. Understanding these sources will help you evaluate the quality and suitability of the recycled plastic for your specific needs.

Supplier Evaluation and Partnership

Partnership with your suppliers is crucial. It is imperative to evaluate their sourcing, processing, and production methods to ensure they meet your product specifications and quality standards. Full visibility into their ecosystem, including their quality controls, tests, and supply chain management, is essential to guarantee the consistency and purity of the recycled plastic.

Location and Transportation

The location of your recycled plastic vendor has a significant impact on transportation costs and speed. Consider vendors located near your manufacturing facility to reduce transportation expenses and time. Additionally, evaluate their logistics capabilities and ensure they align with your requirements for efficiency and cost-effectiveness.

Material Characteristics and Compatibility

Recycled plastic materials come in various forms, such as repro pellets or regrind. Assess the physical characteristics of the recycled plastic, including rigidity, durability, colourfastness, thermal stability, leaching potential, resilience, and density. Ensure that the chosen material is compatible with your manufacturing processes, such as injection moulding or thermoforming, and that it meets your performance requirements without requiring additional complex processes.

Recyclability and Regulations

Consider the recyclability of the recycled plastic you source. Additives, colourants, and compounding can affect the ease of reuse, so plan for these factors during the design and sourcing stages. Stay informed about industry standards and government regulations, especially in regions like Europe, which has stringent guidelines for recycled plastic usage. Ensure that your sourced materials comply with relevant standards to avoid legal and environmental issues.

Community Initiatives and Partnerships

Engaging in community initiatives and partnering with various stakeholders can help develop a sustainable recycling infrastructure. Collaborating with other brands, converters, suppliers, and governments can drive innovation and create a steady source of high-quality recycled plastic. It also helps to address the issue of insufficient consumer recycling, which directly impacts the supply of recycled materials.

Alternative Recycling Methods

Explore alternative recycling methods such as chemical recycling, which can turn plastic back into its raw material, oil. This process has the potential to create an "infinite" recycling system that accepts all types of plastic. Additionally, consider distributed recycling and additive manufacturing (DRAM), where individuals and communities recycle plastic waste into new products using 3D printing and open-source designs, creating a profitable and environmentally friendly approach.

By carefully considering these supply chain and logistics factors, you can make informed decisions when sourcing recycled plastic, contributing to a more sustainable and efficient process.

Explore chemical recycling as an alternative to conventional recycling

Sourcing recycled plastic can be a complex process. There are many factors to consider, such as the type of recycled plastic (e.g., post-consumer or post-industrial), its proximity to your facility, durability, colour safety, and potential for leaching chemicals.

However, chemical recycling, also known as advanced recycling, plastics renewal, or molecular recycling, offers an alternative to conventional recycling methods. Chemical recycling is an umbrella term for various processes, including pyrolysis, gasification, and depolymerization, which break down the chemical structure of plastic waste using heat, pressure, catalysts, and/or solvents to create fuel or new plastic products.

While chemical recycling has been much discussed, there are only 11 constructed plants in the US as of September 2023, and their output remains low while hazardous waste output is high. The health effects of toxins released by these plants can range from respiratory issues to genetic mutations. Additionally, the fuels generated from this process are not regulated under the Clean Air Act.

Despite these concerns, chemical recycling via pyrolysis has been found to have a 50% lower climate change impact and life cycle energy use than energy recovery options. It also generates 2.3 tonnes less CO2 equivalent per tonne than virgin plastic. However, pyrolysis has significantly higher other impacts than mechanical recycling, energy recovery, and virgin plastic production.

As chemical recycling is an emerging technology, its long-term sustainability is still uncertain. Nevertheless, it presents an alternative to conventional recycling methods and has the potential to contribute to the management of plastic waste.

Examine the role of partnerships and community initiatives in sourcing recycled plastic

Partnerships and community initiatives play a crucial role in sourcing recycled plastic. Firstly, companies must view their relationship with suppliers as a partnership rather than a transactional exchange. This involves working closely with suppliers to evaluate and understand their sources and supply chain. Protocols set by third-party plastic credit auditors can provide a framework for responsible sourcing of plastic waste as a raw material.

For instance, Oceanworks, a recycled plastic solutions provider, works with brands to reduce their plastic footprint through integrating recycled content and funding plastic waste removal. Their Plastic Action Platform helps organisations understand their plastic footprint and take steps to reduce it. Similarly, Greenpath offers commercial recycling services, leveraging their experience and knowledge of materials to support companies in sourcing recycled plastic materials for manufacturing.

Community initiatives are also essential in improving the recycling infrastructure and raising awareness. For example, PepsiCo Recycling was launched to improve plastic recycling infrastructure and raise awareness. Additionally, the Responsible Sourcing Initiative is a global program focused on uplifting informal waste workers and delivering responsibly sourced plastics while addressing human rights issues in the plastic recycling value chain. This initiative brings together various stakeholders, including global brands, investors, recycling and collection companies, and waste worker associations, to ensure that plastic waste supply chains support recycled plastics and advance circular economy goals while respecting the rights of informal workers.

Furthermore, partnerships between brands and governments can help shape regulations and drive post-consumer recycled content forward. For instance, regulations like the Extended Producer Responsibility (EPR) and new European Union (EU) regulations require companies to evaluate and report on social and environmental impacts and risks in their supply chains, including the treatment of informal waste workers.

Overall, partnerships and community initiatives are vital in addressing the complex nature of recycled plastic sourcing, ensuring ethical and responsible practices, and advancing circular economy goals.

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