What is PCR Plastic? - KIVO Flexible Plastics

PCR is short for post-consumer recycled. PCR products are made from recycled plastic from discarded materials from households, commercial, industrial and institutional facilities. Post-consumer waste is the world&#;s largest waste stream. Therefore we are constantly looking for ways to reduce the size of this stream. In order to make PCR plastics, waste is converted into raw materials. This makes it a very eco-friendly solution. In the following article we answer frequently asked questions about this material.

For more information, please visit EcoPlas.

How is PCR plastic made?

The production of PCR plastics starts with the collection of post-consumer waste. Through specialised sorting (manual or otherwise), thorough cleaning and reheating and grinding, the PCR granule is produced. This granulate is then used to make new products.

What is the difference regarding other recycling streams?

Another recycling stream is PIR: Post Industrial Recycle of Regrind. This uses post-industrial waste. This is waste generated in the production process of products. This can be material that ended up on the factory floor or material with a production error. Many companies already recycle their own stream of post-industrial waste, making this material unavailable to the free market.

Post-consumer waste, on the other hand, originates at the end user. Examples include paper waste, green waste and plastic packaging that the consumer throws away. This is not yet recycled on a large scale because the loop is larger, which increases the uncertainty in terms of purity and uniformity of the material. As it is the largest waste stream, it is precisely here that most environmental gains can be made.

What is the advantage of PCR plastic over virgin plastic?

Reuse of plastic that has already been made is not only a cost-effective process, but also a waste reduction process. In addition, processing the used plastic requires less water, less fossil fuels and less energy. The use of PCR also has indirect benefits. All the benefits are listed below:

• Less use of fossil resources
• Reduction of CO2 emissions up to 85%
• Less water consumption
• Less energy consumption
• Reduction of the amount of waste
• Can be recycled after use
• It shows consumers that brand owners are concerned about the impact of their plastic packaging on the environment
• Helps to create a circular economy

What are the disadvantages of PCR?

Of course, the material also has disadvantages. For example, PCR plastic may not (yet) be used in the food industry, due to the strict regulations surrounding food safety. Because the course of the material is large, the uncertainty in terms of purity and uniformity of the material increases. As a result, it may also be unclear, for example, whether the material contains harmful substances.

It is also not yet possible to obtain UN approval. This is because practice is still ahead of the legislation. In order to obtain a UN approval, raw material suppliers must be able to give a certain guarantee, which is then laid down in the legislation. Applications for this have already been submitted in Brussels by major parties such as Suez. See question 4.a for more information on UN approval.

Furthermore, some colours of PCR plastic are difficult to make because the material is not completely transparent. Particularly light, transparent and pastel colours are difficult. Colours from the middle range are always possible. If the waste is very well separated manually, even transparent and light colours are possible.

What is a UN approval?

A packaging that has a UN approval means that the packaging has been tested and certified under the supervision of national authorities. The UN approval consists of a number of tests, including air pressure, drop and stacking tests. The approval is based on a specific packaging composition, which includes the closure, type of tape and the absorption material used. Approved packaging is given a UN mark which indicates the type of packaging, packaging group, maximum weight or air pressure, liquid or solid marking, year of production and registration number. The UN marking must always be clearly visible and in a certain size on the packaging at all times.

Which PCR plastic products do we offer?

We already produce clear shrink films with 50% PCR with a thickness of 35my, potting soil films with even 80% PCR from REKS and transparent and translucent collection bags of up to 99% PCR.

Both are made from recycled LDPE/HDPE, only with PCR it is a given that it comes from post-consumer waste. In contrast to rLDPE/rHDPE, where it may also be made from post-industrial waste, for example. Post-industrial waste is already recycled by many companies. This is not always the case for post-consumer waste.

These are just examples of the possibilities with our PCR material. For each situation and application we can, in consultation with the client, look at the opportunities that exist in terms of applicability.

Where does our PCR come from?

The waste streams that are processed into new material come from all over Europe. Current capacity is 10,000 tonnes per year with the aim of doubling this by the end of . Whereas previously these waste flows were shipped in huge quantities from Europe to Asia, or were processed to lower quality (less homogeneous) regranulate within Europe, our REKS recycling plant now offers an answer to the increased export problems and the increasing need for high-quality plastic packaging with recycled content with this capacity. The plant meets all the high European requirements for, for example, water management, energy management, occupational health and safety requirements, REACH and the processing of residual waste. This assures you of a high quality film produced in a safe and responsible manner using certified PCR material.

Learn more about REKS here.

Watch the company clip of REKS below!

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What is PCR Packaging?

PCR, short for post-consumer resin (post-consumer recycled), is an environment-friendly packaging option that is made from recycled plastics, most commonly PET and HDPE plastic products. Instead of being sent to a local landfill, used items such as bottles, milk jugs, buckets, and industrial products like IBC totes and polydrums can be broken down, melted and reconstructed to make a resin material that&#;s then added to create a new product&#;PCR packaging.

PCR packaging is used to propel a continuous cycle of creating various "new" products with used recycled plastics. In addition, according to the United States Environmental Protection Agency (EPA), post-consumer recycled production reduces the reliance of fossil fuels as well as raw materials for its formulation in comparison to virgin resin products.

 

Pros of PCR Packaging

The recycled resin reduces the amount of waste that is landfilled and reduces the use of fossil fuels which, in turn, improves the environmental impact of plastic packaging. PCR packaging appeals to eco-conscious consumers, and, studies suggest that people, particularly generations Gen Z and millennials, are committed to having a positive impact on the environment, indicating PCR plastics are the way of the future.

 

PCR allows manufacturers to produce high-quality products like a virgin resin product would at competitive prices while reducing their environmental impact. The grade of PCR plastics is equally matched with regular plastic film in terms of protection, performance, and strength. Post-consumer resin blocks light, oxygen, and other gases from seeping into the package.

PCR packaging can be suitable for food-contact use if it meets the FDA Guidelines.

These plastics decrease carbon footprints (the total amount of greenhouse gases produced by our actions).

 

Cons of PCR Packaging

The required reheating process in creating PCR plastics can alter the color and clarity of the product depending on the amount of resin that is added. This process does not hinder the function or durability of the bottle. Manufacturers can shy away from using post-consumer resin because the dark properties of the bottle do not fit the aesthetic they want to portray for their packaging.

Benefits of PCR plastic are dependent on the consumer recycling their products.

Price of manufacturing is contingent on the amount of plastics recycled.

 

How Is PCR Used?

After consumers recycle their products, recycling plants sort the bottles according to their plastic type. Because PET and HDPE plastics are most commonly used to manufacture PCR products, these plastics are collected, washed and broken down into resin pellets. The resulting pellets are then reheated, molded and formed into a new product.

PCR can be added in percentages ranging from 10% to 100% along with virgin plastic depending on the manufacturer's preference.

 

If post-consumer resin is used to manufacture a plastic bottle, a higher percentage can impact transparency and color. Some companies choose to incorporate less PCR in their products and more virgin resin so the material can retain the look of virgin resin. For example, if a product is composed of 25% PCR and 75% virgin resin material, then the product will look more like a virgin bottle. Additionally, many PCR plastic bottles are typically intended for products that do not require transparent packaging.

 

What is Virgin Resin?

Virgin resin is the term for new and unused plastic resin without any recycled products to generate an original product. Due to its clean appearance and stable nature, virgin resin is heavily used to produce a wide variety of plastic products.

 

PIR or PCR? Reprocessed vs Recycled

PIR, or post-industrial resin, is reworked plastic produced in the manufacturing process. PIR consists of grinded resins that were collected either from extra scrap parts during the molding stage of production or finished products that did not pass the quality control standards of the original product. Despite never being used before, the material is not considered virgin because it has been put through a second reheating process.

PIR products have not reached the consumer whereas PCR products include used material that's already reached the consumer and returned.

While PIR is reprocessed resin, PCR is made of used and recycled resin. Like PCR packaging, PIR also helps decrease the amount of plastic sent to landfills as well as reduce the demand for raw materials.

 

Is PCR Packaging Biodegradable?

The term biodegradable is defined as the length of time it takes for plastic to fully break down and degrade by the consumption of living microorganisms such as fungi and bacteria. While PCR is a more environmentally friendly option (in comparison to virgin resin) since it's made from recycled plastic, according to The Federal Trade Commission's Green Guides, the plastic itself is not biodegradable unless it is decomposed within a year of being disposed of in landfills, incinerators and recycling plants.

 

What is Post Consumer Resin (PCR) Plastic? PCR&#;s Pros & Cons for Packaging

In today's environmentally conscious world, sustainability has become a significant focus across various industries. One solution gaining momentum is the use of Post-Consumer Recycled (PCR) plastic in packaging. PCR plastic, as its name suggests, is made from recycled materials, specifically consumer waste like plastic bottles and containers. 

By embracing PCR plastic, businesses can significantly reduce their reliance on fossil fuels and raw materials in production, minimizing their environmental impact and footprint.

 

What is PCR Plastic Used For?

PCR plastic finds application in a wide range of industries and products. It is commonly used in the manufacturing of packaging materials such as bottles, jars, and containers for personal care items, cleaning supplies, food, beverages, and more.

 

What is Virgin Resin?

Virgin resin refers to plastic made from new, non-recycled materials. Unlike PCR material, which utilizes post-consumer waste sourced from recycling programs and recycling facilities, virgin resin relies on raw materials derived from fossil fuels. It is commonly used in various industries and packaging applications, offering a wide range of physical properties and customization options. While virgin resin has its place in packaging, the rising popularity of PCR plastic demonstrates the increasing demand for sustainable alternatives in today's plastic materials market.

 

Advantages of PCR Packaging

Using PCR plastic in packaging offers several advantages, contributing to both environmental sustainability and brand reputation. Some key benefits include:

Reduced Carbon Footprint: By utilizing post-consumer waste, PCR plastic reduces the consumption of fossil fuels and energy required in the production of new plastic, resulting in lower greenhouse gas emissions.

Resource Conservation: PCR plastic reduces the demand for virgin resin, conserving valuable natural resources such as petroleum and natural gas.

Waste Minimization: Incorporating PCR plastic into packaging promotes the circular economy by diverting plastic waste from landfills, fully embracing the recycling process and extending the useful life of materials.

Consumer Appeal: As eco-consciousness grows, consumers are increasingly favoring brands that demonstrate their commitment to sustainability. Using PCR packaging allows businesses to align with consumer values and strengthen their brand image.

 

Things to Consider Before Using PCR Packaging

While PCR plastic presents numerous advantages, it is important to consider specific factors before transitioning from virgin resin to PCR packaging. Some considerations include:

Regulatory Compliance: Ensure compliance with regional regulations and certifications related to the use of PCR plastic, as these may vary.

Quality and Performance: Evaluate PCR plastic's physical properties, such as clarity, strength, and barrier properties, to ensure they meet the specific requirements of your product.

Supply and Availability: Assess the availability of PCR plastic in sufficient quantities to meet your packaging needs, considering potential fluctuations in supply chains.

Cost Considerations: Understand the potential cost implications associated with PCR plastic, including any additional processing or sourcing expenses.

 

The rise of PCR plastic in packaging signifies a significant step towards a more sustainable and environmentally friendly future. By harnessing the advantages of PCR plastic and considering important factors, businesses can make informed decisions to reduce their environmental footprint while meeting consumer demands. Embrace the power of PCR plastic and join the journey toward a greener, more responsible approach to eco friendly packaging.

 

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If you want to learn more, please visit our website Is PCR Plastic Recyclable.