Can New Sorting Technologies Contribute to the Recyclability of Plastics?

Manufacturers of plastic packaging are under pressure to make a greater contribution to the circular economy, by producing packaging that is more recyclable and contains more recyclates, among other measures. The next milestone is due to be reached when the EU Packaging Regulation (PPWR) comes into force in 2026.

Against this backdrop, the “Advanced Sorting for Circularity” technology assessment is investigating whether and if so to what extent innovative sorting technologies that have not yet been widely used can advance the recycling and traceability of rigid and flexible plastic packaging. The study by research and consulting firm Eunomia, initiated by packaging group Amcor, collection and sorting technology specialist Tomra, and consumer goods giant PepsiCo, covers the EU member states as well as Norway, Switzerland, and the United Kingdom.

The report methodically identifies polymers and packaging materials that cannot be adequately removed from the waste stream using conventional processes and returned to the recycling loop as raw materials for new FMCG packaging via traditional mechanical recycling. The experts are also evaluating innovative technologies that could be used to classify and sort packaging that has been emptied at home.

Three technical alternatives have been shortlisted and their cost-performance has been explored in greater depth: sensor-based object recognition and chemical and digital markers (watermarks).

Collecting More Material

In their conclusion, the authors of the study explain that the recycling potential of most rigid plastic packaging can be exploited even without cost-intensive new technology, reports the Lebensmittelzeitung. To achieve the future recycling rates required by the EU, it is advisable to collect more material and optimize conventional sorting techniques. Formats made of high-density polyethylene (HDPE) and polypropylene (PP), which are conventionally difficult to identify and in which “contact-sensitive” filling goods such as cosmetics, food, or pharmaceutical products are packaged, could be extracted from the waste stream using object recognition. This innovative alternative is cost-efficient in so far that both chemical and digital markers – with roughly the same material yield – require the installation of special systems. As a specialist in reverse vending, Tomra has already gained a great deal of expertise with sensor-based object recognition.

In the case of flexible plastic sleeves, the authors of the study also found that innovative technology does not result in a significantly higher material yield for recycling. The use of contact-sensitive packaging depends on the results of pending studies on cost and performance data, they say. In the event that these turn out to be similar to those for rigid qualities, object recognition is also recommended as a supplementary identification method.

In their overall assessment, the technology experts predict that object recognition will establish itself as a more cost-effective addition to existing sorting processes on the way to a better circular economy. However, both the plastics industry and political decision-makers should consider whether the additional financial burden required is accompanied by sufficient additional benefits from the use of markers as a mass market solution.

“Our results provide a clear direction for targeted investment and innovation in sorting technologies. They highlight the importance of aligning technology decisions with specific recycling targets and the individual requirements of different types of packaging,” summarizes Andy Grant, head of the study project at Eunomia.

As the industry moves towards meeting EU targets for recycled content, this nuanced understanding will be crucial as we move towards more effective and sustainable recycling processes for plastic packaging.