Sofia Martinez
Plastic coatings are commonly used in the packaging industry to improve functions such as water resistance, tear strength, and heat sealability. In the context of boxes, plastic coatings are often applied as a thin film to cardboard boxes used in consumer packaging, enhancing the box's durability and protecting its graphics and designs. This type of coating is referred to as C1S (Coated, 1 Side) in the printing industry. While plastic coatings provide functional benefits, they can complicate the recycling process, requiring specialized methods to separate the plastic from the cardboard.
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What You'll Learn
Plastic corrugated boxes
Additionally, plastic corrugated boxes are water and chemical-resistant, making them reusable and reducing waste. They also provide enhanced merchandise protection, with features like lids for additional security and hand holes for easy transport. The manufacturer's joint in the box design prevents crowning in stacks and allows for bundling without deformation.
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Plastic coatings for paper
Plastic-coated paper is paper that has been coated with a mixture of materials or a polymer to improve qualities such as weight, surface gloss, smoothness, water resistance, tear strength, and reduced ink absorbency. The most common type of plastic coating used in the packaging industry is polyethylene (LDPE), with polyolefin extrusion coating, silicone, and wax coating also being used.
Liquid packaging board cartons typically contain 74% paper, 22% plastic, and 4% aluminium. Frozen food cartons usually contain 80% paper and 20% plastic. Plastic-coated paper is most used in the food and drink packaging industry, with applications including milk and juice cartons, paper cups, and photographic paper.
The plastic coating provides an excellent barrier against water and grease, making the packaging watertight and waterproof. It can also be customised with a printed logo and can include mesh reinforcement to provide greater resistance to tearing.
Plastic coatings can make paper recycling more difficult, as they must be separated from the paper during the recycling process. Some plastic laminations can be separated, and if the coated paper is shredded prior to recycling, the degree of separation is higher. However, most plastic-coated papers are not suited for composting, and the non-biodegradable plastic components can contribute to the global microplastics waste problem.
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Plastic coatings for cardboard
Plastic coatings are applied to cardboard to improve its functionality, such as water resistance, tear strength, and abrasion resistance. This is particularly important for packaging that needs to withstand moisture, bacteria, and fungi to prolong the shelf life of its contents. For example, plastic coatings are often used in food packaging to protect the food during transport and storage, thereby reducing food waste.
However, plastic coatings on cardboard can complicate the recycling process. While some recycling facilities can handle cardboard with plastic coatings, the plastic and cardboard typically need to be separated and recycled in different facilities. As a result, cardboard with plastic coatings is generally less sustainable than pure cardboard.
To address this issue, researchers have been working on developing more sustainable coatings for cardboard. One example is a water-based coating with a synthetic resin to stabilize polymer particles, which can provide a barrier against both water and grease. This coating has the advantage of being thinner and more easily peelable, making the cardboard more suitable for recycling.
Another alternative to plastic-coated cardboard is Liquiguard, a waterproof coating that is fully biodegradable and recyclable. It is safe for direct food contact and provides resistance to oil, grease, and moisture. Liquiguard-coated cardboard can be reused multiple times and is suitable for packaging a wide range of products, including food items and industrial components.
Overall, while plastic coatings on cardboard can serve important functions, there is a growing focus on developing more sustainable and environmentally friendly alternatives that can provide the same level of protection and performance. These innovations aim to reduce plastic waste and improve the recyclability of coated cardboard materials.
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Plastic coatings for recycling
Plastic coatings are commonly used in the packaging industry, especially for cardboard boxes. These coatings improve functionality by making the surface water-resistant, tear-proof, and abrasion-resistant. They also enable heat sealing and provide a glossy finish. However, plastic coatings can complicate the recycling process, as the coated layers need to be separated from the paper or cardboard. This challenge has prompted the development of innovative de-coating processes, such as chemical washes, to enhance the recyclability of coated materials.
The recycling industry is continuously evolving to address the challenges posed by plastic coatings. One critical step is the removal of coatings from plastic surfaces, which can significantly improve the usability and value of reclaimed materials. For instance, Plastic Reclaiming Services has developed a de-coating process that utilizes a chemical wash to remove metal, clear, and paint coatings from polymers. This process not only promotes recycling efficiency but also expands the range of applications for recycled plastics.
The de-coating process plays a vital role in reducing landfill waste and conserving resources. By removing the original coatings, recycled plastics can be more easily combined with virgin or other recycled materials, creating high-quality and high-performance composites. This versatility increases the economic viability of plastic recycling and contributes to the sustainability of the industry by reducing the need for new plastic production.
Additionally, advancements in recycling technologies, such as the DECOAT project, focus on recovering substrate materials while also exploring the recovery of coating and paint materials. These technologies aim to improve the recycling value chain and promote a circular economy. The DECOAT process involves identifying the additives used in a product so that the correct triggering agent can be deployed for effective recycling.
The reuse and repurposing of industrial and consumer waste polyesters are also gaining traction. The ability to melt process bulk thermoplastics into useful forms, such as pellets or flakes, offers a convenient solution for the collection and separation of waste materials. These recycled materials can be upcycled and used in protective coatings, reducing the reliance on virgin petroleum products. Overall, the development of innovative de-coating technologies and recycling processes is crucial for enhancing the sustainability and economic viability of the plastics industry.
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Plastic straps for closing boxes
Plastic straps, also known as plastic strapping, are commonly used to close and secure boxes for shipping and transportation. They are particularly useful for larger or heavier boxes that require additional reinforcement. Plastic straps can be made from polyethylene terephthalate (PET), which is a type of plastic that exhibits excellent resistance to elongation and can maintain tension for extended periods. PET strapping is also highly sustainable, as it can be manufactured from recycled materials and is recyclable after use.
Another type of plastic strapping is polypropylene (PP) strap, which is made from polypropylene plastic. PP straps are known for their high strength and durability, making them suitable for securing heavy or bulky items. However, it's important to note that PP straps degrade with each use, so their recyclability may be limited compared to PET straps.
Plastic straps are often used in conjunction with other packaging materials, such as glue, staples, and tape, to ensure the secure closure of boxes. They can be applied manually or with strapping machines, depending on the specific application and volume of boxes being processed.
In addition to their use in closing boxes, plastic straps can also be utilised for unitizing loads of corrugated boxes, securing pallet loads of various products, and maintaining package integrity during storage and transportation. The choice between PET and PP straps depends on factors such as the specific application, environmental considerations, and the availability of recycling programs.
While plastic straps offer significant advantages in terms of securing and reinforcing packages, it's worth mentioning that they can pose challenges in recycling cardboard boxes. Some recycling facilities may require the removal or separation of plastic straps before accepting cardboard for recycling. Proper handling and disposal of plastic straps are important to minimise their environmental impact and contribute to sustainable practices.
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