Closing material cycles: Innovations in liquid carton recycling

Michael Brandl: The liquid carton producers have been committed to high-quality recycling for over 20 years, starting from collection, through sorting, to the recovery of valuable materials such as paper fibre, polyolefins and aluminium. The specialised paper mills have continuously developed their processing technologies to achieve high fibre yields with minimal use of production resources. In this respect, we are already at a very high level. We are currently experiencing a real innovation boost in the still new recycling of non-fibre components (PolyAl): Supported by the manufacturers of liquid cartons, various mechanical, physical and solvent-based technologies have been developed that enable PolyAl to be used for various applications for recyclates. The daily experiences in processing are immediately invested in further developments and improvements, so that tailored solutions can be offered for all demands. The range of applications already extends from injection moulding applications to film production. Due to the growing availability of input material through the increase in recycling of liquid cartons, interest in this raw material is also increasing, and thus its innovative power is expanding. The goal is to offer products that can replace fossil raw materials with recyclates from PolyAl in many areas of plastic applications. There will still be many refinements and improvements to come, as well as in an ecological sense.

Michael Brandl: In the waste hierarchy, recycling plays a central role in extending the sustainability concept to as many areas as possible. A successful circular economy also means that the principle of material-to-material (and not product-to-product) is ecologically valuable. The ecological benefit does not solely result from the materials used, but from their significance for the content, the consumer and the transport routes (keyword: food safety and food spoilage). And of course, the type and composition of the materials should be suitable for the recycling processes along the value chain. For this purpose, our industry has developed ‘Design for Recycling Guidelines’ and will soon introduce a complete ‘Recyclability Assessment Protocol’.

Michael Brandl: With the PPWR, new and very ambitious targets regarding the recyclability of packaging (at least 70% by 2030) and the return of packaging volumes to the recycling process (EU-wide 55% by 2035) have been set. Otherwise, there is indeed a threat of a ban on such packaging. The main focus of our industries is on the improved collection and sorting of liquid cartons, where there is a great need for catching up and improvement in some regions. In parallel, the expansion of recycling capacities for both the paper component (+40% by 2035) and the non-fibre component (+80% by 2035) is being promoted nationwide. We are confident that with a higher available collection volume, existing capacities can be expanded and new ones built. The interest of recyclers is certainly present. 

Michael Brandl: The greatest challenge lies in the collection, and here in Germany in the proper separation of materials, especially by the consumer! Regulations such as prescribed collection quotas for liquid cartons or nationwide uniform, understandable guidelines for separating waste materials are correct, but they must fit into the entire value chain and also be properly addressed and monitored. It makes no sense to charge the industry for the consumers’ misconduct. Much more sensible are educational measures or a monitored ‘trash can discipline’ to increase both the amount collected in bins/bags, and at the same time improve the quality of the collected mix by correctly assigning recyclables to the right bins. On one hand, this saves gigantic and expensive sorting efforts in specialised facilities and naturally ensures better recycling possibilities for packaging when more pure-grade packaging with less contamination enters the recycling process. Whether incentives, or rather penalties, are helpful is certainly a matter of different kinds of assessment. In any case, any kind of appropriate and expert information from different sources, such as the current campaign ‘Waste separation works!’ is very welcome.