Plastics Technology: Blog /rss/blog A collection of the most recent blog posts. Fri, 23 Jun 2023 14:04:47 -0400 Purpose-Built System Enhances Capacity and Flexibility for Recycler A Boston recycler invested in a turnkey shredding, granulation and elutriation system to expand its plastics reclaim 911±¬ÁÏÍø. Originally operating a single truck,  Boston waste-management company  recently embarked on a mission to provide alternatives to traditional waste disposal, helping 911±¬ÁÏÍøes dispose of recoverable plastics that may otherwise be landfill-bound.

Recycling line.

Save That Stuff’s new recycling line processes hangers. (Photos: Cumberland)

Save that Stuff, which was founded in 1990 by CEO Erik Levy,  provides waste-management services for a wide range of materials. It recently found opportunities to expand its plastic recycling operations, including a contract to recycle PP plastic clothes hangers from a major U.S. retailer. To do so, they needed to upgrade their recycling equipment. They turned to Cumberland.

“They had an older system and had been looking for a solution for a while, something that would add flexibility and also modernize their operation,” said Cory Gagnon, senior marketing specialist at Cumberland.

The team at Cumberland worked with Save that Stuff to devise a turnkey solution that would not only increase the volume of plastics that they could process, and deal with the particular challenges of reprocessing hangers, but also provide the flexibility to prepare for future 911±¬ÁÏÍø opportunities.

Cumberland provided a turnkey solution, comprised primarily of a Vecoplan shredder, a Cumberland granulator and a Sterling Blower elutriation system. The basics of the system are the same as would be used for any rigid plastic.

“There’s really no difference when it comes to cutting-chamber style, so we are looking at wear packages and options to help the equipment last longer, sizing for throughput, and adding options,” says Joe Platek, 911±¬ÁÏÍø development manager at Cumberland.

A configuration option particular to the Save that Stuff project addressed the need to deal with hangers, a product composition that requires special consideration.
 

Recycling Assembled Products with Multiple Materials

The hangers being processed by Save that Stuff are of the type assembled from both plastic (PP) and metal components (such as the clips used to hold pants) often used in retail environments.

“It can go through the shredder, but we don’t recommend any kind of metal going through a granulator at all,” explains Andrea Parrillo, regional sales manager at Cumberland.

Conveyer sorting metal from plastic.

Handling equipment magnetically separates metal components (at right) from plastic for recycling.
 

To prevent equipment damage and downstream contamination, these components can be liberated and sorted from the material stream. For this purpose, Cumberland provided a magnetic conveyor system between the shredder and granulator. After the hangers are broken up by the shredder, any ferrous components are pulled up and out of the material stream to prevent them getting into the granulator.

The system also includes metal detection, which alerts the operator if any metal does slip through the sorting step, so that they can take corrective action. After granulation, the PP material is passed to the elutriation system, which suspends and pulls dusts and fines off of the material, leaving the PP granules ready to ship.
 

Purpose-Built Size-Reduction System with a Flexible Future

Capacity of the new system is estimated to be 2000 lb/hr. The new capacity and versatility have encouraged Save that Stuff to look for new opportunities to increase their plastics recycling operations, currently about 10% of the company’s overall 911±¬ÁÏÍø.

Since implementing the new system, the company has found opportunities in recycling HDPE barrels and spools of the type used to store cable. These products may not have need for metal separation, but many plastic waste products do. Beyond hangers, examples include bumper fascias and spray bottle caps. 

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Wed, 31 May 2023 00:00:00 -0400 FTC Panels Discuss the Green Guides, Recyclability, and Consumer Perception Public feedback is being solicited on the definition of recyclable and other issues associated with marketing claims. In December, the FTC announced it would seek public comments on potential revision to the Guides for the Use of Environmental Marketing Claims, also known as the “green guides”, which were last updated in 2012. The guides advise marketers on how to avoid running afoul of the Federal Trade Commission Act, , which prohibits ''unfair or deceptive acts or practices in or affecting commerce. ''

The guidance covers general environmental claims and several specific claims. Among those likely to be of interest to plastic manufacturers are: compostable, degradable, free-of, and — of course — recyclable and recycled content. On May 23rd the FTC hosted a to discuss marketing claims around recyclability.

Resin code 6

The commonly used symbol for PS, a theoretically and technically but not practically nor economically recyclable material. Many have expressed concern that incorporation of the chasing arrows symbol misleads consumers by implying recyclability.
Photo Credit: Public Domain

James Kohm, associate director at the FTC Bureau of Consumer Protection, opened the event by describing the mandate of the FTC, not to set environmental policy but to prevent consumer deception by marketing claims. “The green guides are the FTC’s interpretation of Section 5, which prohibits deceptive advertising. Deceptive claims look not to the definition of the claim, but how reasonable consumers interpret that claim,” says Kohm.

Marketing Claims and Recycling Realities

Panelists provided the moderators, FTC attorneys Hampton Newsome and Julia Solomon Ensor, with their views on  the current state of recycling and of current recyclability marketing claims.

Public enthusiasm for recycling remains high, and is motivated by a broader desire for sustainability. “People are really trying to do their part in helping the environment and they want to buy earth friendly, sustainable products and are willing to pay more for them,” said Bonnie Patten, executive director at , a nonprofit consumer advocacy group. Dr. Quinta Warren, associate director of sustainability policy at Consumer Reports, shared that 70% of consumers recycle at least often. “We are already in a good place because we don’t have to convince consumers to recycle, our surveys show they already want to,” says Warren.

This trend has encouraged brands to align their marketing claims with this enthusiasm. Marketers can make qualified or unqualified claims of recyclability. “Check Locally” is an example of a common qualification of a marketing claim, an unqualified claim would simply say “recyclable”.

Currently the green guides advise marketers to avoid making an unqualified claim of recyclability unless 60% of the consumers to whom it is marketed have access to recycling for that product.

Anne Germain, COO at the , says that the organization’s members are still reporting contamination rates as high as 20%, and attributed this to misunderstandings about what is accepted by recycling programs. “We do think labeling has a significant impact on that contamination and perception,” says Germain. Germain described some of the biggest problems faced by MRFs are caused by plastic films, which foul up machinery and cause frequent shut downs; and lithium batteries, which are causing an alarming and steadily increasing number of fires in recycling facilities.

Discussion zeroed in on plastics as an area of wide variation between localities and potential misinterpretation. “Plastics are where we get 98% of the confusion,” says Adam Reidel, manager at the Environmental Management Office for Arlington County, VA. 

Collection is generally strong where corresponding end markets are strong, such as for PET bottles, but there is variation in how lower value materials are handled. Arlington County, for instance, collects resin codes 3, 4, 6, and 7 although Reidel expressed doubt that these materials were being reprocessed.

Forty million Americans have no curbside collection at all, according to comments from Kate Bailey, chief policy officer at the . But that could change. “There has never been more momentum to improve recycling, and in particular plastics recycling, than we are seeing right now,” says Bailey.

Consumer Perceptions of Recyclable Claims

“Our research shows that what people trust and how they trust the interpretation of claims directly impacts whether or not they choose to recycle.” says Sarah Dearman, chief innovation officer at . Dearman argued that smart, qualified claims would balance the need to for transparency while still enabling a pathway for packaging that is making steady progress toward recyclability.

Panelists were asked to consider what unqualified recyclable claims mean to customers.“When people see a recycling symbol or message on a package, they expect that it is going to be made into something new,” says Dearman, “our research shows that over and over.”

Karen Hagerman, director of the at GreenBlue, described survey results on the spectrum from theoretical recyclability to 100% actually recycled. “We found the most agreement in the category that the thing is recycled most of the time, but not always. We found this to be encouraging as it is in alignment with the definition set forth in the green guides,” says Hagerman.

Do Chasing Arrows Imply a Recyclability Claim?

Several panelists pointed to current implementation of resin identification codes as a source of confusion. Usually, the resin codes are surrounded by the chasing arrows symbol. “The chasing arrows mean recycling everywhere else except with plastic,” says Anne Germain. According to Peter Blair, policy director at Just Zero, only 8% of survey respondents understood that the resin code was not a guarantee of recyclability.

changed its standard for the use of resin identification codes in 2013 for this very reason, replacing the arrows with an unbroken triangle. However, adoption of the new design has been challenged. Many state laws mandate the use of the chasing arrows symbol. California has adopted new legislation requiring a disclaimer when the chasing arrows appear on plastic packaging that is not “recyclable” according to standards set by the state.

Future of the Green Guides

Panelists also were asked to consider how the FTC can, within its current authority, help resolve issues with customer deception in recyclability claims. Responses varied. “The onus of sorting through green claims should not fall on consumers,” says Dr. Quinta Warren, “We need the FTC to set clear guidelines that corporations have to follow, but also that consumers can use.”

Raissa Lerner, deputy attorney general in the State of California, cited recent cases  where courts had interpreted recyclable claims as indicating only technical recyclability. “Maybe it could be made more explicit that we are talking about the end user, not just putting it in the bin but all the way through, because the consumer expectation: that they are the beginning of that process.”

Patrick Krieger, vice president for sustainability at the , drew a distinction between demonstrating the capability of recycling, and demonstrating that something is actually being recycled. “The term recyclable, and especially when we use it in an unqualified way, is that you have the ability to and not is actually (recycled),” says Krieger, “You do have to be able to make it into a finished product again, but that is different from ‘must’ because of many economic considerations outside of the producers’ control”. 

Peter DePasquale, VP of government affairs for Kuerig Dr. Pepper, suggested  design for recyclability as a consideration. “We have MRFs and recyclers who say they want products and packages in a certain way so there can be an end market, and I think part of the analysis should be if that design for recyclability is adhering to well-recognized design guides.”

More Opportunities to be Heard

The FTC is seeking additional public comment, which will be accepted until June 13, 2023. Instruction for submitting comment can be found on . The EPA is also seeking public comment, on its . Comments are due June 16, 2023.

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Mon, 29 May 2023 00:00:00 -0400 Molding and Moldmaking Conference Agendas Finalized August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today. Collocating for the second time, the long-running and all new conferences will provide attendees dedicated injection molding and moldmaking in the morning, with combined sessions bringing the groups together in the afternoon to learn about big picture topics.

Attendees can move freely between the two events, taking in the tracks and presentations that resonate most with their 911±¬ÁÏÍøes and the challenges they face. More than 40 presentations will be given over the two days — today and map out your Molding and Moldmaking plan.

Thought leaders at suppliers, OEMs, molders and moldmakers will share their knowledge on the most important trends and technologies of the day in a combined environment designed to spark collaboration. Attendees won’t just feed their minds, with meals and refreshment breaks included on both days of the event.

On the Molding side, major topics covered include sustainability automation, simulation, additive manufacturing and more, with presenters from equipment, material and software suppliers, as well as OEMs, molders and moldmakers.

Early registrants, and those in groups, get a discount, so be sure to .

microphone

See who will be stepping up to the mic at Molding and Moldmaking 2023.
Photo Credit: Getty

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Fri, 26 May 2023 00:25:00 -0400 Twin-Screw Compounding Trends What's new in extrusion? Leistritz talks with the Plastics Technology team on hot topics in extrusion including, biopolymers and recycled materials.  /blog/post/twin-screw-extrusion-trends-in-technology Wed, 24 May 2023 00:00:00 -0400 Latest Data on Bottled Water Shows Continued Strong Growth Bottled water’s volume surpassed soft drinks for the first time in 2016 and has done so every year since.
IBWA shares data on strong growth of bottled water
Photo Credit: International Bottled Water Association

We recently heard from the (IBWA) that new data from the (BMC) shows that bottled water has “reached new peaks in both volume consumed and sales”. IBWA has been an authoritative source of information on all types of bottled water—from spring, mineral, and purified to artesian and sparkling since its founding in 1958. BMC is a leading source of U.S. and global data and consulting for beverages ranging from bottled water and carbonated soft drinks, to beer, fruit beverages and new age beverages.

BMC’s latest data shows that bottled water’s total volume sold in 2022 was 15.9 billion gallons, its highest volume ever, surpassing carbonated soft drinks for the seventh year in a row. In terms of retail dollars, 2022 sales approached $46 billion, up from $40.8 billion in 2021. For more than a decade, consumers have been increasingly choosing bottled water instead of less-healthy packaged drinks. Bottled water’s volume surpassed soft drinks for the first time in 2016 and has done so every year since.

According to BMC’s editorial director John G. Rodwan, “Numerous qualities account for bottled water’s unceasing resonance with U.S. consumers, including its associations with healthfulness, convenience, safety, and value. Consumers’ thirst for beverages that offer benefits beyond refreshment alone also contributed to the fundamental hydrating beverage’s rise in the beverage standings. Bottled water’s zero-calorie status and its lack of artificial ingredients appeal to many consumers. Even where tap water may be safe and readily available, people may prefer bottled water, which they often believe tastes better.”

Americans consumed, on average, 46.5 gallons of bottled water in 2022, compared to 36 gallons of soda. Consumer demand for bottled water has significantly contributed to the industry’s growth (30% since 2012), as people continue to switch from other less-healthy packaged drinks to bottled water. So much so, that nine out of 10 Americans (91%) want bottled water to be available wherever other drinks are sold, according to a survey conducted on behalf of the IBWA) by The Harris Poll.

Said IBWA’s v.p. of communications Jill Culora, “People are choosing to drink bottled water because it is a healthy beverage choice, having zero calories and no caffeine or additives, and it has the added benefit of packaging that is 100% recyclable. Not only are bottled water containers 100% recyclable (including the cap) but they also use much less plastic than soda and other packaged beverages.”

While the health benefits are a definite factor in opting for bottled water vs. other beverages as shown by the data, this editor and her colleagues respectfully have doubts, at least for the time being, about the latter part of Ms. Culora’s statement. As colleague Matt Naitove put it, “I don't imagine that anyone chooses bottled water over a carbonated beverage because the water bottle uses less plastic.”  Still, IBWA shares some interesting data and comments that pertain to recyclability of plastic water bottles.

â–ª  On average, soda containers use 252% more PET plastic than bottled water containers (22.2 grams vs. 8.8 grams for 16.9-ounce containers). Soft drinks and other sugary beverages need thicker plastic containers due to their carbonation and/or bottling processes.

Even with continuing growth and increased consumption, bottled water still has the smallest impact on the environment—thanks to the fact that it has the smallest water and energy use footprint of any packaged beverage. On average, only 1.39 liters of water (including the 1 liter of water consumed) and 0.21 mega joules of energy are used to produce 1 liter of finished bottled water.

 â–ª  Most bottled water is packaged in 100% recyclable PET and HDPE, plastics most recognized by consumers as being recyclable and the most recycled plastics in the world. Bottled water’s recyclability distinguishes it from other common plastic products that are truly “single-use,” such as non-recyclable plastic items (e.g., straws, cutlery, and plates); certain food and goods packaging (e.g., film, heat-sealed and multi-layered laminate bags) and containers (e.g., non-PET, HDPE, and PC bottles and tubs). In addition, PET plastic bottled water containers are the most recognized by consumers as being recyclable, which is likely the reason why they are the most recycled containers in U.S. curbside recycling programs. PET plastic bottled water containers are a valuable resource because they can be recycled and used over and over again.

 â–ª  Recycling facilities know that there is a huge industry demand for post-consumer PET and HDPE. Many bottled water companies use recycled PET and HDPE to create new bottles, which helps to reduce their environmental impact. Moreover, bottled water drinkers recycle more often than drinkers of other beverages. Of all the PET containers recycled through curbside collections systems, bottled water containers make up approximately 49%. Empty bottled water containers should always be returned or placed in a recycling bin, but when they are not, they make up 3.3% of all drink packaging that ends up in landfills, and only 0.02% of all landfill waste.

 â–ª  Studies have shown that bottled water containers are also not a major source of ocean pollution and microplastics. The vast majority of ocean plastic comes from sources other than the United States. In fact, if the U.S. were to completely eliminate all plastic use, the effort would only result in a 0.25% reduction of ocean plastics, data from Oxford University’s Our World In Data website shows. A striking statistic is that bottled water accounts for less than 1.58% of all plastics used in the U.S., which means we are talking about 1.58% of 0.25%.

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Mon, 22 May 2023 00:00:00 -0400 Recycling Terminology Can Be a Minefield, So We Should Tread Lightly Loose propagation of terms like “recyclable” and “compostable” has already brought down government regulations on labeling. The plastics and packaging industries should take that to heart with other recycle-related language. Like “monomaterial” for example.

New Polyfoil EcoPro squeeze-tube body structure from Hoffmann Neopac is praised for excellent barrier properties, 30% reduced wall thickness, use of up to 60% PCR and recyclability in the HDPE stream. EVOH constitutes around 2% of the structure – is that truly “mono-material”? (Photo: Hoffmann Neopac)

Today everybody wants to be considered “green,” but nobody wants to be accused of “greenwashing.” Unfortunately, being overly free with progressive-sounding environmental terms ends up constricting our freedom. We’ve already been told by government regulators when we can or can’t say something is “recyclable” or “compostable.” There are ongoing discussions at various regulatory levels about when we can call something “recycled” and even what does or does not constitute “recycling.”

Many in the plastics and packaging industries have taken this lesson to heart. Nowadays, when I see announcements about the sustainability of materials, they are often backed up by certifications from recognized authorities. Nonetheless, I see evidence of the need for continued vigilance to avoid stepping into verbal potholes.

Just last week, I saw an announcement from the Swiss-based global packaging firm about the launch of a new product at the Luxe Pack NY trade show the week before. The new Polyfoil EcoPro squeeze tubes are described as “mono-material double barrier tubes … ideal for personal care and cosmetic products.” Available in capacities of 50 to 200 ml, these tubes contain up to 60% EU food-grade post-consumer recycled (PCR) HDPE and have a body wall thickness of 0.35 mm, which is 30% less than the company’s standard Polyfoil barrier tubes. Their CO2 footprint is said to be 40% less than “standard coex tubes.” They can use virgin or recycled (up to 70%) EU food-grade HDPE in the shoulder and flip-top or screw cap.

Hoffmann Neopac says the new tubes come with EU food compliance certification as well as a Grade A recyclability rating from the EU’s sustainability verification organization, and Suez Grade A rating from , the French-based global provider of “circular solutions” in water and waste materials.

I was intrigued by the description of these tubes as “mono-material” and “double barrier” as well as the company’s claim that they are “fully recyclable in the HDPE stream.” On a Neopac devoted to the product I found the “exploded view” of the laminate layer structure shown here. You’ll notice, as I did, that there are two layers that combine EVOH with HDPE: One is a coextruded layer and the other an MDO-HDPE layer with a 3-micron EVOH adhesive-bonded layer. I guess that’s what they mean by “double barrier.” There are also two adhesive layers. Not shown here is the “overcoated” outer layer of the tube, containing up to 70% PCR-HDPE.

So, strictly speaking, we’re not dealing with a “mono-material” tube body – it comprises two materials, or really three, counting the adhesive. The key, however, is that the EVOH constitutes only around 2% of the structure, so the tube is certified recyclable in the HDPE stream – just as if it were mono-material HDPE. A member of the Neopac team confirmed that this is what really counts, more than the precise material composition, and is how the “mono-material” label is justified.

Okay, I can see that argument. But it still leaves me a bit uneasy. I wrote here recently about the accelerating trend toward “mono-material” packaging (and some durables, too). I was impressed by the creativity that allows all-polyolefin structures to replace barriers based on aluminum foil, metallization or incompatible resins such as nylon, PVDC or PET. Even then, I noticed that some “all-polyolefin” products, such as new pouches from Toppan, Inc. of Japan, actually employ vapor-deposited layers of aluminum oxide or silicon oxide (i.e., “glass”), though they're still recyclable in polyolefin streams.

Burdened with an editor’s commitment to precision and accuracy in language, I’m beginning to wonder about the prudence of packaging manufacturers tying themselves to language like “mono-material” and “all-polyolefin” when that’s not truly the case. Better to stick with the real point: “recyclable in the PE (or PP) stream.” Without diminishing the importance of this evolution in packaging toward greater recyclability, let’s not get off on the wrong foot by mis-labeling the product and possibly inviting regulatory correction later on.

Plastics and packaging producers are often criticized for supposedly exaggerating the achievements of recycling. So let’s not open ourselves up to another claim of misrepresentation. The real story of package recyclability in the PE or PP stream is a big deal on its own. When the facts are favorable, stick with the facts.

Your comments are welcome. (mnaitove@ptonline.com)

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Fri, 19 May 2023 00:00:00 -0400 Plastic Bank Marks 10 Years and 88,000 Tons of Plastic Waste Reclaimed Company sets up local exchange centers to divert plastic waste otherwise likely to end up in the ocean. celebrated its 10-year anniversary, announcing it had surpassed a milestone of helping global communities divert 80 million kg (176 million pounds) of plastic waste. The company has enabled over 500 recycling communities in Southeast Asia, Latin America, and Africa.

Man with cart for plastic.

A Plastic Bank collection community member in Indonesia.
Photo Credit: Plastic Bank

Plastic Bank focuses on preventing discarded plastics from reaching the ocean. Collection community members gather plastic waste from areas within 31 miles (50 km) of coastlines and waterways, where mismanaged waste is considered “ocean-bound”, meaning that the risk of being washed into the sea is high. Once in the ocean, plastic waste can interfere with biological systems. 

In exchange for dropping off the material at local collection branches, members receive income and other benefits including insurance, social, financial, and digital services.

From the collection branches, the recyclate is brought to recycling facilities for processing into Plastic Bank’s “Social Plastic”, in flake or pellet form. Social Plastic materials include recycled PET, HDPE, and LDPE. The multinational household product companies and are among the producers that have incorporated Social Plastic into their product packaging.

The exchanges are tracked using an app based on blockchain technology, which helps secure compensation of community members and creates an audit trail for impact reporting that includes the type of plastic exchanged, the location, weight, time, and more. This data and the provided visualization tools enable the supporting partners of Plastic Bank to track and demonstrate the impact of their support.

In a parallel of the concept of carbon neutrality, partners set goals of offsetting the plastic produced by their operations with an equivalent amount of plastic waste recovered through support of Plastic Bank, thus achieving “plastic neutrality.” announced in January that the company would expand its offerings of plastic neutral contact lenses, and has set a goal of achieving plastic neutrality by 2030.

Plastic Bank was founded in 2013 by David Katz and Shaun Frankson. The  company has set its own ambitious goals for the future, targeting 2.2 billion lb/yr (1 billion kg/yr) in plastic waste removal, 1 billion people impacted, and 1 billion dollars in value.

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Tue, 16 May 2023 00:00:00 -0400 Drones and Injection Molding Ready for Takeoff Drones and unmanned aerial vehicles (UAV) are approaching an inflection point where their production volumes — and functionality — will increasingly point to injection molding. A confluence of the broader trends of lightweighting, reshoring and automation that seem to be impacting so many different sectors are combining in the unmanned aerial vehicle (UAV) space in a manner that could pose huge potential for injection molders. Last week, I had the opportunity to at the show in Denver. Co-hosted by AUVSI (Assn. for Uncrewed Vehicles International) and Messe Düsseldorf North America, the event promises to help attendees “design the plan for an autonomous future.”

As UAVs seek to take on an array of new tasks from and to and , they’re approaching broader acceptance and point to a ubiquitous presence in our not-so-distant future. If those and other markets continue to grow, the build volumes for these vehicles will soon favor the economics of plastics injection molding over current production methods and materials.

At Xponential, the panel discussed just that, with Blue Halo, a maker of UAVs and unmanned aircraft systems (UAS), swapping out a machined aluminum chassis for its newest craft, which has civilian and military uses, for an injection molded one. The switch provided the benefits familiar to most when it comes to metal-to-plastics conversions: lighter weight, parts consolidation, easier assembly, with some additional bonuses include the ability to be coated and offer greater chemical and heat resistance (to wit: I was shown video of a laser trying and failing to impact the molded chassis).

Lowering the weight of these vehicles allows them to either carry more of a load, which could take the shape of more gadgetry, i.e. sensors, cameras, etc., or actual load if they’re doing civilian or military deliveries. Shedding weight also means they can fly further or faster. Often times lowering the craft’s mass leads to a combo of those two: slightly longer/faster trips with slightly higher cargo.

Automation and Reshoring Angles

Just as robots and automation in the plastics manufacturing space are often tasked with relieving humans from dirty, dangerous or repetitive tasks, UAVs can let people avoid dangerous or monotonous jobs like surveilling battlefield enemies, mapping out forest fires or shuttling other humans around.

On the reshoring front, the world’s largest maker of drones, China-based DJI (Da-Jiang Innovations), has been facing increasing regulatory pressure from states and the U.S. government, including . These moves, including the proposed , introduced this year in the U.S. Senate, would open the market up to U.S. makers of UAVs.

Injection molders may only need to look skyward for their newest market opportunity.

BlueHalo Intense Eye UAS chassis

BlueHalo’s Intense Eye is a 750-mm class 4 rotor Vertical Take Off and Landing (VTOL) UAS with commercial and military possibilities.
Photo Credit: Alpine Advanced Materials

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Mon, 15 May 2023 00:00:00 -0400 The Future of Automation in Injection Molding Are you automating enough? At #PTXPO23 we spoke with leaders in automation and injection molding about the current state of automation and what’s in store for the future. /blog/post/the-future-of-automation-in-injection-molding Fri, 12 May 2023 00:00:00 -0400 All-PP Packaging is More than Likely to Make its Mark in the Monomaterial Trend Borealis and partners have developed a new PP monomaterial food pouch with high barrier and compatibility for mechanical recycling of PP.   My colleagues and I have been increasingly reporting over the last few years on the monomaterial trend, particularly in the food and non-food packaging arena. Check out these two blogs from earlier this year on Monomaterial’ Trend in Packaging and Beyond Will Only Thrive and In Sustainable Packaging, the Word is ‘Monomaterial’.

Borealis Group and industry partner develop over 95% PP food pouch
Photo Credit: Borealis Group

All-PE monomaterial structures, particularly in the flexible packaging sector, including standup pouches, have pretty much ruled in terms of commercial success. But, we have been expecting all-PP packaging to make up ground as the overall plastics industry’s aim for a circular economy in pretty much all market sectors has become a key if not dominant consideration. An excellent example is the latest development by Borealis Group and value chain industry partners who have created a monomaterial food pouch containing over 95% PP and designed for recycling.

High barrier packaging is used to preserve and protect foodstuffs that are sensitive to moisture, oxygen, aromas, and light, like dry ingredients and powders, coffee, and snack foods. Producers and consumers benefit from the longer shelf life and reduced food waste made possible by these convenient high barrier pouches. In the extrusion lamination process, laminating PP cast and BOPP (biaxially oriented polypropylene) films yields mono PP laminates with uniquely advantageous properties. These include high barrier and stiffness, and excellent sealing performance.

Using conventional adhesion lamination structures, producers have previously been able to obtain pouch laminate materials containing approximately 90% PP. However, by pooling their respective areas of expertise, Borealis and value chain partners have now been able to boost the share of PP to over 95%. When processed within dedicated mechanical recycling streams for PP, this monomaterial pouch yields greater volumes of high-quality recyclate fit for use in non-food, flexible PP packaging applications.

I asked Borealis sources to confirm the structure of this first prototype and they noted that this type of high-performance flexible packaging is predominantly achieved by the production of a laminate. ‘In our case—two different BOPP films and one cast PP film are glued together to form a high-barrier mono-PP laminate.”  They note that this more sustainable high-barrier monomaterial PP packaging format offers a range of benefits for the blown and cast film extrusion processes as well as for brand owners and end consumers.

For one thing, it can help meet ambitious recycling and waste reduction targets set forth in the EU’s Packaging and Packaging Waste Regulation (PPWR) as well as eco-modulation criteria for Extended Producer Responsibility (EPR) programs. They see this packaging as the ideal format with which to fulfil the principle aims of the PPWR: improve recyclability, grow the market for recycled content, and reduce packaging waste.

The high barrier pouch made of over 95% PP is said to demonstrate excellent seal strength and hermetic sealing properties thanks to the material solutions and production expertise contributed by each of the value chain partners involved in this project. Commercially available polyolefins in the Borealis PP extrusion coating and lamination grade portfolio reportedly offer stable processability and good laminate bond strength. These were used in tandem with tie layers contributed by the , a leading international manufacturer of specialty chemicals, including polyolefin-based tie resins.

Meanwhile, as a global leader in the development and manufacture of specialty BOPP films, contributed to this innovative solution for recyclable packaging. With locations in Europe, America, and China. Profol, known for its innovative cast PP films and lightweight composites, produced the cast films. Based in Finland and operating in 38 countries, characterizes it self as “providing solutions that enhance wellbeing and convenience for consumers around the world”,  contributed innovative laminates to the new monomaterial pouch.

While eco-modulated EPR fees based on packaging recyclability credentials and recycled content may differ among EU Member States, the new monomaterial pouch made of over 95% PP meets the CEFLEX (Circular Economy for Flexible Packaging) definition of “fully compatible to mechanical recycling PP.” It is thus a cost-saving alternative to conventional pouch formats composed of a greater number of different materials.

Noted Peter Voortmans, Borealis’ global commercial director for consumer products, “In re-inventing essentials for sustainable living, our aim is to uphold the integrity and quality of packaging materials while ensuring that these convenient formats are more and more circular. We are very proud of this value chain collaboration. It equips our partners and customers with yet another viable and more sustainable solution to help manage the updated requirements of the PPWR.”

 

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