Post-Consumer Resin - Understanding the quality-performance linkage for packaging
Lead Research Organisation:
University of Liverpool
Department Name: Chemistry
Abstract
Home and personal care products are often contained in bottles made of high-density polyethylene (HDPE) and about 150,000 tonnes of this packaging are produced annually. The resulting post-consumer plastic is then collected, sorted and mechanically recycled. This mechanical recycling process involves grinding, washing and then extruding to give pellets known as post-consumer resin (PCR). Less than 69,000 tonnes of HDPE PCR are produced annually, which means that more than half of the plastic packaging is going to landfill rather than being recycled. PCR can be incorporated into HDPE packaging to replace virgin plastic which saves on waste and is also more efficient in terms of carbon emissions. However, one of the major issues with using PCR in packaging is that it is a variable material. It may contain different grades of plastic, it can be contaminated with other materials and the recycling process itself can lead to degradation of the plastic. This means that incorporation of PCR into bottles tends to result in reduction in performance of the packaging. The variability in PCR makes it harder for companies to use PCR in packaging, it increases the cost of using PCR and ultimately places an economic penalty on the increased use of PCR. There is currently insufficient scientific understanding of the changes that occur to HDPE during recycling which means that it is challenging to address issues with the inconsistency of PCR. This means there is an urgent need to understand the quality-performance linkage for PCR in packaging.
This ambitious project brings together an interdisciplinary team from the University of Liverpool and University of Manchester to improve the mechanical recycling of HDPE. We will enable rapid delivery towards the goals of the Plastic Pact for this important waste stream, and reduce plastic waste and increase recycling by 2025, by making use of existing plastics and infrastructure. We will generate a detailed understanding of the chemistry and property relationship of PCR. This new knowledge will allow PCRs to be produced with improved performance in packaging and also to prevent degradation in recycling. Simultaneously, we will understand how this disruption within the supply and demand for PCR will impact supply chain. This understanding will allow interventions to be selected that deliver the greatest economic, social and environmental benefits. This research will therefore facilitate improving the quality of PCR in packaging, increasing the value of PCR which will then drive greater investment in plastics recycling.
This ambitious project brings together an interdisciplinary team from the University of Liverpool and University of Manchester to improve the mechanical recycling of HDPE. We will enable rapid delivery towards the goals of the Plastic Pact for this important waste stream, and reduce plastic waste and increase recycling by 2025, by making use of existing plastics and infrastructure. We will generate a detailed understanding of the chemistry and property relationship of PCR. This new knowledge will allow PCRs to be produced with improved performance in packaging and also to prevent degradation in recycling. Simultaneously, we will understand how this disruption within the supply and demand for PCR will impact supply chain. This understanding will allow interventions to be selected that deliver the greatest economic, social and environmental benefits. This research will therefore facilitate improving the quality of PCR in packaging, increasing the value of PCR which will then drive greater investment in plastics recycling.
Publications
Rose A
(2024)
Characterisation of formulated high-density poly(ethylene) by magic angle spinning nuclear magnetic resonance
in Polymer Chemistry
Description | We have identified factors that control the quality of recycled high density polyethylene. Using this knowledge it is possible for producers of recycled plastics to improve the quality of their recycled plastics. We have demonstrated that a selection of simple and common characterisation methods can be used to predict the quality of recycled high density polyethylene. For companies that buy high density polyethylene, this means that companies can identify recycled plastics that meet their requirements. |
Exploitation Route | We are already working with industry to embed our processes into their practice. |
Sectors | Agriculture Food and Drink Construction Environment Manufacturing including Industrial Biotechology |
Description | Bright Green Plastics have used the data generated from our project to identify the differences in their recycled plastics (PCRs) products and those of the highest-performing PCRs. They have been using this insight to improve their products. |
First Year Of Impact | 2022 |
Sector | Chemicals,Manufacturing, including Industrial Biotechology |
Impact Types | Economic |
Description | A4I Round 11 - Evolving the sustainable single use wash bowl- Understanding how the stability against detergents can be obtained without the use of forever chemicals |
Amount | £9,315,504 (GBP) |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 04/2024 |
End | 10/2024 |
Description | Advancing Recycled Plastics: Predictive Tool for Packaging Quality- IAA Proof of Concept |
Amount | £10,122,598 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 09/2023 |
End | 05/2024 |
Description | Enhancing Packaging Sustainability: Understanding How The Properties of Recycled Poly(ethylene Terephthalate) (rPET) Control Bottle Performance- IAA Secondment |
Amount | £35,982,306 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 03/2024 |
End | 02/2026 |
Description | Using machine learning and high throughput analysis to understand and reduce the effect of contamination in recycled plastics |
Amount | £3,562 (GBP) |
Organisation | Henry Royce Institute |
Sector | Academic/University |
Country | United Kingdom |
Start | 06/2022 |
End | 09/2022 |
Description | Collaboration with Unilever |
Organisation | Unilever |
Department | Unilever UK R&D Centre Port Sunlight |
Country | United Kingdom |
Sector | Private |
PI Contribution | Our research feeds into Unilever's decision making for the use of recycled plastics in packaging. |
Collaborator Contribution | Unilever have provided samples for us to analyse, they have shared the key performance requirements for recycled plastics in packaging. They have committed to doing bottle tests on plastic samples that we select. |
Impact | There are no outputs at this stage. This is a multi-disciplinary collaboration that covers chemistry, materials science and supply chain management. |
Start Year | 2021 |
Title | Enabling project partner to make evidence-based decisions about new infrastructure to enhance their product |
Description | Our characterisation of recycled plastic showed that our project partner could improve their recycled plastic products by investing in new sorting and washing facilities that would allow them to avoid specific types of contamination. |
Type Of Technology | New/Improved Technique/Technology |
Year Produced | 2022 |
Impact | Partner was able to improve the quality of their product |
Description | Presented at Materials Research Exchange 2022 |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | Tom McDonald presented the talk titled Post-Consumer Resin - Understanding the quality-performance linkage for packaging at Materials Research Exchange 2022 |
Year(s) Of Engagement Activity | 2022 |
URL | https://iuk.ktn-uk.org/events/materials-research-exchange-mre-2022/ |
Description | Presented at Smart Sustainability Plastics Packaging: Shaping the Future of Plastics Research |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | To disseminate the activities and outputs arising from a selection of SSPP projects |
Year(s) Of Engagement Activity | 2024 |
URL | https://pureportal.strath.ac.uk/en/activities/sspp-shaping-the-future-of-plastics-research |
Description | Presenting at Global Research and Innovation in Plastics Sustainability, March 2021 |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | Presenting at Global Research and Innovation in Plastics Sustainability, Tom McDonald gave a talk on Changes that occur in plastic upon mechanical recycling - challenges and solutions. The event was attended by an industrial and research-based audience |
Year(s) Of Engagement Activity | 2021 |