One of the key challenges to the circular economy resides in the extraction of materials from the recycling stream that even sophisticated recycling facilities have long deemed by-products or waste.
These materials, often considered low-value, include plastic films and other difficult-to-recycle components that are typically landfilled or incinerated. Yet, as our understanding of waste and our recycling technologies evolve, so does the recognition of the untapped potential within these overlooked streams.
This innovation offers a blueprint for how other industries can reimagine their waste streams and turn them into valuable resources.
Plastic films, for instance, play a crucial role in modern society, used in everything from food packaging to agricultural applications. In the UK alone, approximately 895,000 tonnes of flexible packaging are placed on the market each year, equating to around 215 billion items.
Despite this substantial amount, consumer packaging, which constitutes 25% of this volume, remains vastly under-recycled, with less than 15% of local councils collecting it from households. A paltry 8% of this material is ultimately recycled.
This stark reality underscores the urgent need for innovative solutions that can transform this waste into high-value materials, especially as the UK gears up for nationwide collection schemes by 2027.
The global picture is equally concerning, with recent figures indicating that Europe demands around 11 million tonnes of flexible films annually, yet only 2.4 million tonnes are recycled, translating to a recycling rate of less than 20 percent.
The vast majority of these films, which include materials such as LDPE (Low-Density Polyethylene) and LLDPE (Linear Low-Density Polyethylene), are used in food packaging and other consumer-targeted products. Consequently, these films frequently find their way into post-consumer waste streams, further complicating the recycling process.
However, two pioneering projects are shining a light on how these seemingly low-value waste streams can be reimagined and repurposed into valuable resources through innovative processing technologies.
These projects, funded by the Welsh Government and commissioned by WRAP Cymru, offer a glimpse into the future of recycling, where even the most challenging materials can be transformed into high-performance products with strong green credentials.
WRAP Cymru’s goal is to accelerate the circular economy by increasing the use of recycled materials in products. To achieve this, they have run a series of supply chain projects designed to demonstrate how technical challenges in using recycled materials, including some of the most awkward to recycle materials such as MRF rejects, can be overcome. The projects also explored the economic and environmental benefits of doing so to support the Welsh Government’s ambitious aim for Wales to become net zero by 2050.
Revitalising the circular economy
Based in Swansea, South Wales, Fiberight’s primary focus is on recovering paper fibre from incoming waste. A significant by-product of this process is post-consumer plastic film – a material traditionally seen as problematic and low-value due to contamination and compositional complexity.
Recognising the potential within this waste stream, Nextek, highly experienced in plastic recycling innovation, proposed an intensive washing and cleaning process to upgrade the quality of the post-consumer film. Fiberight’s existing washing process, although effective to some extent, does not entirely remove all contaminants. Nextek’s solution involves a high-intensity washing process provided by HydroDyn, a German company specialising in advanced cleaning technologies for the plastic recycling industry.
These projects represent a paradigm shift in how we perceive and manage waste.
The HydroDyn process consists of three stages: a cold wash (HydroClean) that removes 99.5% of extrinsic contamination, a hot wash (HydroSuperClean) that further reduces contamination levels, and a final rinsing step (HydroPURE) that leaves the material virtually free of impurities. The cleaned film is then extruded and melt-filtered, resulting in a material that can be evaluated for its suitability in new applications, such as film blowing.
The outcome of this project was very positive. The high-performance wash by HydroDyn produced visually clean films that demonstrated excellent mechanical properties when reprocessed. These films, originally classified as highly contaminated MRF rejects, were successfully transformed back into new film applications, such as mulch films, waterproofing membranes, and composites for the agricultural and construction sectors.
Furthermore, the project highlighted the importance of characterising the mechanical properties of the processed film resin to determine its suitability for different applications. The treated film showed higher stiffness and elongation compared to virgin material, proving that with the right treatment, even low-value waste streams could contribute to the circular economy.
The broader implications of this project are significant. By transforming MRF rejects into high-value products, industries can not only increase recycling rates but also meet regulatory requirements, such as the UK plastic packaging tax, which mandates a minimum of 30% recycled plastic content in single-use products. This innovation offers a blueprint for how other industries can reimagine their waste streams and turn them into valuable resources, driving both environmental and economic benefits.
Breakthrough collaboration
In a separate but equally groundbreaking project, WRAP Cymru, in collaboration with Nextek and several industry partners, sought to tackle the recycling of mixed plastic waste derived from MRF and ASR (Auto Shredder Residue) rejects. The project’s goal was to demonstrate that these challenging waste streams, which are typically destined for landfill or incineration, could be repurposed into high-quality building materials.
The project focused on manufacturing composite decking products using a blend of post-consumer films from Fiberight’s MRF recovery operations and mixed plastics from MBA Polymers, a company that specialises in recycling complex waste streams from the automotive and electronic sectors.
The materials also included plastic-coated paper cups, another challenging waste stream that often ends up in landfill.
The initial step in the project involved characterising the waste streams from Fiberight and MBA Polymers to identify the most suitable materials for composite production. As with the first case study this was followed by a rigorous pre-treatment process to remove contaminants and ensure the materials were of high enough quality for use in manufacturing.
Here too the project’s results were extremely positive as they reached all the technical targets Nextek had set on material that was previously destined for waste. The composite decking products produced from the agglomerated waste materials exceeded the stiffness and water absorption requirements of standard decking products. The addition of up to 30% of these waste-derived materials not only met but surpassed industry specifications, demonstrating the potential for large-scale production and commercial viability.
This project showcased how these waste streams, often considered low-value and problematic, could be transformed into resources with significant environmental and economic benefits. By incorporating these materials into long-term applications such as decking, the project not only diverted waste from landfill but also reduced the need for virgin materials, once again contributing to the circular economy.
The success of this project also underscores the importance of collaboration between recyclers, manufacturers, and end markets. By bringing these stakeholders together, the project created new material options that can drive industry competitiveness and reduce CO2 emissions.
The potential for scaling this model across other sectors and regions is immense, offering a pathway towards more sustainable resource management and product development.
Rethinking waste as a resource
These projects represent a paradigm shift in how we perceive and manage waste. By taking what was once considered low-value waste streams and transforming them into high-performance materials, these initiatives demonstrate the power of innovation in driving the circular economy forward.
The global challenges posed by plastic waste and other difficult-to-recycle materials are immense, but these case studies offer a hopeful vision of what is possible. Through the application of advanced processing technologies and strategic collaboration, even the most problematic waste streams can be repurposed into valuable resources with strong green credentials.
As the world moves towards a more sustainable future, it is these type of projects that serve as a reminder that the materials we often overlook as waste can, in fact, be the building blocks of a circular economy. By redefining waste as a resource, we can unlock new opportunities for innovation, competitiveness, and environmental stewardship, ensuring that our planet’s resources are used wisely and sustainably for generations to come.
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This article was co-authored by: Dr Jonathan Mitchell, UK Project Manager at Nextek, who has over 10 years’ experience in the recycling industry. Jon has postgraduate qualifications in Polymer Engineering and Polymer composites. Jon has considerable experience in plastics processing and polymer material science and is skilled in material analysis and process improvement and research program management.
Jon has had experience in high volume, high purity plastics processing for a leading manufacturer in the medical field, involving process optimisation and problem solving within a production environment. He is also experienced in project planning and management as well as production for improved material utilisation and productivity. His specialisations also cover biopolymers and composites based on natural fibres.
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The post A new glimpse into the future of recycling first appeared on Innovators magazine.