TECHNICAL DESIGNING REPORT FOR A CIRCULAR ECONOMY

Recyclability of polyolefin-based flexible packaging

June 2020 Phase 1 2 3

Foreword

The CEFLEX initiative, Designing for a Circular The underlying principles of the guidance respect the role of all Economy (D4ACE) Guidelines, will facilitate the packaging materials and recognise the preference in plastic waste streams development of a circular economy for flexible destined for , which prioritises packaging by 2025. Only with near universal polyolefin-based mono-materials over mixed polyolefins, over mixed plastics, adoption of these and related guidelines will this over mixed multi-materials.

ambition be realised. The guidance contained in this document should not be interpreted as a bale specification. Bale specifications Work to develop the guidance provided based materials which can be readily must indeed be based on the quality in this document commenced in identified, sorted and recycled. needs of the end markets that will 2017. The limited guidelines which use the recycled materials from existed for flexible packaging at CEFLEX has consequently chosen flexible packaging. this time, together with the Ellen to focus on driving collection and MacArthur Foundation Project Barrier recycling rates to ensure these The CEFLEX guidelines have been guidelines, formed a starting point for materials are returned to the economy. developed in good faith by a broad the CEFLEX guidelines. Realising this ambition will require representation from the entire flexible the collection of all flexible packaging packaging value chain. The document This document represents the work of and the availability of the required is offered for all to adopt and use on a over 150 CEFLEX stakeholders from all infrastructure to sort and recycle it, voluntary basis. parts of the flexible packaging value in all European countries. chain to identify best practice in the collection, sorting and recycling of These guidelines recognise that The CEFLEX initiative polyolefin-based flexible packaging. delivering the circular economy for flexible packaging begins by designing The guidance is forward-looking to all flexible packaging to be sortable and 2025 but is based on what is considered recyclable, whilst not compromising best practice in 2020 for the ‘best in on product protection and providing class’ sorting and mechanical recycling necessary product information. infrastructure available in Europe. At the same time, it recognises that the capabilities of sorting systems and mechanical recycling are likely to develop significantly in the coming five years. For this reason, the guidelines will be reviewed regularly and updated with input from the entire flexible packaging value chain.

CEFLEX recognises that waste prevention and reuse are important parts of the circular economy. The urgency for the industry however is to stop leakage into the environment.

Today (2020), only two-thirds of European countries collect flexible packaging with other dry recyclables despite approximately 70-80% of all consumer flexible packaging being reported as mono-material polyolefin- 4 5

1 Introduction Contents

2 Designing for a circular economy 1 Introduction 6 Size, shape and construction...... 32 Density...... 32 Background and context ...... 6 ...... 33 3 Purpose EU flexible packaging volumes in 2019...... 7 Pigments ...... 33 and approach Additives and fillers ...... 34 Inks and lacquers...... 34 2 Designing for a circular economy 9 ...... 35 Additional features ...... 35 4 Designing for recyclability in a circular economy ...... 9 End-of-life processes The CEFLEX initiative ...... 10 7 Use of recycled materials from flexible packaging 36 3 Purpose and approach of Designing 5 Phase 1 for a Circular Economy Guidelines 12 guidelines 8 Next steps 38 Purpose...... 12 Phased approach ...... 12 Phase 2 guidelines ...... 38 Terminology and definitions ...... 13 Future proofing ...... 38 6 Methodology ...... 14 D4ACE principles 9 Appendices 40 4 Building understanding of the end-of-life processes Appendix 1: Definitions and terminology...... 40 7 for flexible packaging 15 Appendix 2: Materials and their properties...... 46 Recycled materials Packaging disposal...... 15 Appendix 3: D4ACE phase 1 guidelines summary...... 48 Collection...... 16 Sortability...... 16 Recyclability...... 18 Tables 8 Next steps Table 1: Phase 1 Designed for Recyclability flexible packaging structures...... 21 5 Phase 1 Designing for a Circular Economy Guidelines 20 Table 2: Phase 2 flexible packaging structures ...... 21

9 Figures Appendices 6 Circular economy flexible packaging design principles 22 Figure 1: Flexible packaging design requirements...... 9 General design principles...... 22 Figure 2: 5 steps to build a circular economy for flexible packaging...... 11 Guidelines for designing polyolefin-based flexible packaging for recyclability...... 24 Figure 3: Sorting process for ...... 17 Material selection ...... 26 Figure 4: Flexible plastic mechanical recycling process...... 19 choice ...... 27 Figure 5: Preference for streams from post-consumer and paper labels...... 30 polyolefin-based flexible packaging...... 23 foil ...... 30 Figure 6: Elements of a flexible packaging structure ...... 24 Barrier layers and ...... 31 Figure 7: Examples of flexible packaging structures ...... 25 6 7

1 Introduction 1 Introduction

2 Designing for a circular economy Background and context EU flexible packaging volumes in 2019

3 1 Designing products and packaging for Purpose Flexible packaging is an essential part of many The total consumer and approach recyclability in a circular economy is elements of everyday life. It is a resource- a key part of making the transition household flexible efficient packaging choice which plays a key role to ‘circular’. packaging market in in protecting food and other products, preventing For flexible packaging this starts with Europe is estimated to 4 designing it to be easily sorted once End-of-life food waste, minimising the use of resources and collected at the end of its life cycle, processes be just under 3.7 million providing important packaging functionality. to be suitable for efficient and high- 5 quality recycling and ultimately for tonnes per annum . those recycled materials to be used in new market applications. Flexible packaging represents half of measurement point in the European Of this, approximately 70-80% 5 food primary packaging in Europe (in waste legislation (2019). (3 million tonnes) is reported as Phase 1 In addition to designing for recyclability, product units) while accounting for only mono- (PE), mono- guidelines However, as circular thinking permeates the move to become circular will one sixth of the packaging material (PP) or potentially a 2 Europe, there is a societal requirement require the value chain to develop, used (in weight) . The wide-ranging polyolefin PE/PP mix6,7. benefits of flexible packaging, such as to shift from focusing solely on meeting implement and adopt a wider spectrum legislative targets, to end of life systems of options and solutions. its low weight and thus minimal use of These polyolefin-based materials 6 materials, lead to it being increasingly which offer solutions to collect, sort CEFLEX is calling on the flexible can generally be regarded as being D4ACE used. However, these properties also and recycle all packaging, preventing principles packaging value chain to: ‘Designed for Recyclability’ because mean consumer flexible packaging it from leaking into the environment, 3 Review existing flexible packaging the processes do exist to sort and can be challenging to collect, sort and returning it to the economy and portfolios and evaluate which recycle them. In other words, it is recycle economically. replacing virgin materials. structures fulfil the designing for technically feasible to recycle these types of flexible packaging. 7 This is one reason it is still not collected This concept of a circular economy is recyclability in a circular economy Recycled for recycling in all European countries, increasingly recognised as the solution requirement. However, the processes and materials but also because the current legislated to the issues resulting from a ‘take- Evaluate what changes can be made infrastructure required to collect, sort weight-based packaging recycling make-dispose’ approach and is based to further improve and optimise the 4 and recycle post-consumer flexible targets for plastics and other materials on the following key principles : design and end of life sorting and packaging are not yet widely established can be met by only collecting rigid Design out waste and pollution recycling processes for structures that across the whole of Europe, nor is it packaging. This is no longer the Keep products and materials in use do not currently fulfil the ‘Designed 8 uniform or harmonised. So, while the with the higher targets and recycling Regenerate natural systems for Recyclability’ requirements. Next steps - For packaging design this could materials can be considered as being these materials is already proven at (PA), polyethylene terephthalate be by providing the required ‘Designed for Recyclability’, this flexible industrial scale in some European (PET), ethylene vinyl alcohol (EVOH) functionality from a mono-material packaging can only be considered countries (for example in Germany, as well as other in addition equivalent where possible or by ‘recyclable’ in those countries where The Netherlands, Italy, Spain and to polyolefins. These structures are CEFLEX definition of flexible packaging ensuring the structure disrupting the infrastructure, capability and end several other countries). In addition generally used when specific properties 9 the recyclable material streams markets are already in place. to the polyolefin-based streams are required such as a barrier against Appendices Flexible packaging structures typically bend easily and can include , pouches, , , removable lidding/liners and wraps. Flexible can be identified and removed. mentioned above, paper-based oxygen or moisture, or improved The first phase of the CEFLEX guidelines packaging structures can be single or multi-layered, using a variety of - For improved sorting and and aluminium-containing flexible mechanical strength. and the focus of this document is on the materials including , paper, or any combination recycling processes this could packaging structures are addressed ‘Designed for Recyclability’ polyolefin- of these. The construction may be plain, printed, coated and/or laminated. include identification of materials where there is existing knowledge Greater understanding of how these through enhanced optical based flexible packaging (mono-PE, about their sortability and recyclability. types of flexible packaging can be Flexible packaging is most commonly used to protect fast moving sorting, mechanical recycling mono-PP and PE/PP mixes). This is sorted and recycled is required. Any consumer goods products such as confectionery, snack foods, frozen process development and new, because as stated above this material The remaining 20-30% of consumer existing knowledge or current practices foods, bakery, fresh produce, meat, dairy, pet food, processed foods, emerging technologies. makes up the largest proportion of flexible packaging includes multi- on the sorting and recycling of these cosmetics, personal care, household detergents, beverage /can Use these guidelines as a tool when the post-consumer flexible packaging material structures containing multi-materials is included in this wrappings, pharmaceuticals, medical and other technical products. designing and specifying new flexible waste stream and because the ability other functional materials, such as document, but this part of the post- packaging structures. to sort and mechanically recycle aluminium foil, paper, polyamide consumer flexible packaging waste

1 CEFLEX definition of flexible packaging context of key pieces of legislation; Waste Framework 4 https://www.ellenmacarthurfoundation.org/ 5 2016 data: 3,987,000 tonnes including exports. 6 Refer to CEFLEX definitions to provide robust data on the proportions of mono- 2 Flexible Packaging Europe study with ifeu Directive, Packaging and Packaging Waste Directive Estimate based on data from ‘Plastics – the facts 7 CEFLEX is undertaking a waste compositional material and multi-material structures 3 These guidelines should be considered within the and the Landfill Directive 2016’ and ‘FPE Market Report Summary 2016’ analysis study of post-consumer flexible packaging 8 9

1 Introduction 2 Designing for a circular economy 2 Designing for a circular economy

3 Designing for recyclability in a circular economy Purpose and approach Recycling has a central facilities throughout Europe as we opportunity to innovate and develop transition to a circular economy. solutions to make flexible packaging role to play in enabling circular by addressing both design and 4 When flexible packaging was not widely end of life challenges. End-of-life flexible packaging to collected for recycling at end of life, it processes contribute effectively to made good business sense to focus The CEFLEX guidelines recognise on designing it simply to provide the and are consistent with the waste a circular economy and required functionality with minimum hierarchy of reduce, reuse, recycle, resource use, thereby minimising recover and dispose. Solutions that 5 after waste prevention, product and packaging waste. move packaging design towards the Phase 1 this is where most top of the hierarchy will be preferred guidelines This remains key in a circular economy, except where this increases the risk of progress is expected to but an equally important objective is to product waste. design flexible packaging so that it will be made in the short to be correctly disposed of, collected and Compromising the protective qualities efficiently sorted into suitable material 6 medium term. of packaging to improve its recyclability D4ACE fractions for recycling. These sorted will typically have a higher cost and principles materials must be recyclable into ‘new’ associated environmental impact than materials that can be used in market producing flexible packaging which Designing for Recyclability is a applications, displacing virgin material. is not recycled but which delivers the requirement that will be aided by stream will be the focus of the second required product protection. The guidelines in this document are not a legal the development and harmonisation The packaging design process therefore 7 phase of the CEFLEX guidelines. of collection, sorting and recycling presents the value chain with an Recycled requirement, but a tool intended to provide advice materials All parts of the flexible packaging value chain have a role to play. Brand and support to brand owners, retailers, packaging Figure 1 owners and retailers need to specify, and their value chains in designing design and place on the market flexible packaging which is ‘Designed flexible packaging to be circular. It is important to 8 for Recyclability’ so the recyclable Next steps waste streams are collected and made note these guidelines are not (yet) developed to Flexible packaging design requirements available for sorting and recycling the stage where they can be used as the basis for according to the value of the materials. a ‘recyclability accreditation’ and should not be Core design requirement End of life design requirement Other parts of the value chain can, 9 and need to, contribute to this in used to make such a claim. Appendices parallel including material producers, film producers and packaging Product Usage Information Marketing Collection Sortability Recyclability converters, as well as equipment and protection technology suppliers. flexible packaging and facilitate the further afield. Consequently, the development of end markets. information and guidance presented This will boost confidence in the in this document may be applicable to waste collection, sorting and Although the CEFLEX initiative and other regions of the world, but there recycling sector, where investment guidelines are focused on Europe8, it is may be important local and regional is required to develop and establish recognised that many of the challenges differences that are not reflected in new infrastructure for post-consumer faced in Europe are also relevant this guide. Designing for a Circular Economy

8 The focus of the CEFLEX initiative is on the continent of Europe 10 11

1 Figure 2 Introduction The CEFLEX initiative

The Circular Economy for Flexible Packaging Designing for a Circular Economy 2 (D4ACE) guidelines are a key deliverable 5 STEPS 9 Designing (CEFLEX) initiative is a collaboration of European of the CEFLEX initiative. CEFLEX aims to for a circular ensure that by embedding circularity in to Build a Circular Economy for Flexible Packaging economy companies, associations and organisations the design phase, the flexible packaging representing the entire value chain of flexible made and placed on the market can be collected and sorted effectively ion ct packaging. Together, we work to make all flexible so recycled materials can be used in e 3 ll Purpose sustainable end market applications. o packaging in Europe circular by 2025. C and approach CEFLEX recognises the capabilities of sorting systems and mechanical The initiative is committed to avoiding CEFLEX vision and roadmap recycling are likely to develop waste and pollution by redesigning significantly in the coming five years, 4 Our aim is to enable collection of all End-of-life consumer flexible packaging and potentially enabling structures ts g flexible packaging and recycle 80% of it e tin processes ensuring appropriate collection and currently considered to be non- rk 1 r into new valuable materials; becoming a o recycling infrastructure in all European recyclable, to be recycled. Enhanced S M countries. either new packaging or flowing back mechanical recycling will also need 80% into the wider circular economy. to be augmented by the development This will enable used flexible packaging of other technologies. Development PE 5 PP Phase 1 to be cost effectively collected, recycled Our vision is a Europe of chemical recycling infrastructure 5 2 guidelines and sustainable end markets developed will also be required to periodically to ensure resources are returned to the where flexible ‘renew’ and rebuild the base polymer economy to be used again and again. packaging is integral properties, to remove contaminants, residual fractions and recycle items Stakeholders are invited to identify and which are too small to be handled 6 to a truly circular and participate as representatives in one of by traditional mechanical recycling D4ACE 3 five groups, reflecting the role they play sustainable future. processes. Wherever possible, these 4 principles gy n in the flexible packaging value chain. future developments have been taken lo sig Together, this is our ‘Mission Circular’; no e into consideration in this document, h d They are: to create multiple lives for flexible recognising that not all of them will c e e R Material producers including plastic, packaging materials. be realised and there will be new T 7 paper and aluminium as well as inks, technologies not yet considered. Recycled To achieve it, a 5-step roadmap to materials coatings, adhesives and additives Film producers and packaging build a circular economy for flexible CEFLEX encourages all users and converters packaging has been endorsed by specifiers of flexible packaging to Brand owners and retailers CEFLEX stakeholders, together with critically review their existing and new Waste collectors, sorters and a set of actions needed by each part flexible packaging portfolios against 8 recyclers of the value chain. the D4ACE guidelines. Wherever Next steps Technology suppliers, end users and possible changes should be made that others Delivering it targets an established allow end-of-life flexible packaging to 1 2 3 4 5 collection, sorting and reprocessing be more easily sorted and recycled

They collaborate and deliver activities infrastructure and economy for post- without critically compromising Drive collection Sort and recycle Redesign Identify End markets of ALL flexible the suitable mono- multi-material solutions for all recycled across seven thematic workstreams, consumer flexible packaging across product protection or increasing packaging for material fractions flexible packaging to and develop flexible packaging working to identify and implement Europe by 2025. It will be based on product waste. 9 sorting and recycling mono-materials with capabilities to sort materials Appendices solutions to achieve the CEFLEX vision. end-of-life technologies and processes which deliver the best economic, existing recycling and recycle the technical and environmental outcome streams where remaining fractions for a circular economy. possible

These 5 steps have been endorsed by the CEFLEX stakeholders together with a set of actions needed by each part of the flexible packaging value chain

9 https://ceflex.eu/ 12 13

1 Introduction 3 Purpose and approach Terminology and definitions of Designing for CEFLEX recognises that definitions provided in this document may differ to those being proposed by other organisations. 2 Designing As consensus is reached for each definition and these are adopted by organisations such as International Organisation for for a circular Standardisation (ISO) and European Standards (EN), CEFLEX will align the definitions in this document accordingly. economy a Circular Economy Guidelines A full list of terminology and definitions is included in Appendix 1, but the key terms used within this document are: 3 Contains predominantly one material type, either PE (LDPE, LLDPE, HDPE), PP, PET, Purpose Mono-material and approach aluminium, paper or other.

For plastics, this should be seen to mean >90% of one polymer type as this is the upper Purpose Phased approach threshold when the other elements such as adhesives, additives and inks are included. 4 The exception is if one of the minor components such as paper or biodegradable plastics will End-of-life The purpose of the CEFLEX guidelines is The CEFLEX D4ACE guidelines are being delivered in phases (see Section 5, processes disrupt the plastic mechanical recycling process. to provide informed support, guidance Tables 1 and 2). and information to all in the value chain responsible for specifying and Bi-axially oriented and non-oriented forms of the same base polymer are considered to be designing consumer flexible packaging. Phase 1 guidelines mono-material as are PE and PP copolymers and homopolymers as long as they have a neutral or positive effect on the recycled stream. 5 The focus is to provide information and guidance on the types of polyolefin- Phase 1 The guidelines are based on widely based flexible packaging that can currently be described as ‘Designed for guidelines This definition applies equally to paper and aluminium foil flexible packaging although the accepted principles, industry practice Recyclability’. or derived from actual testing to verify actual percentage may vary depending on the recycling process (to be confirmed in phase 2). the sorting and recycling limits of Polyolefin-based structures that can be sorted and recycled using existing flexible packaging structures. industrial scale technologies and processes Multi-material11 Contains more than one layer of material where no material type is > 90% and the other layers 6 This is supported by either test/trial data, by commercial practices are made of different materials. D4ACE Additional guidance is provided to somewhere in Europe or by broad consensus of the CEFLEX stakeholders principles explain what happens to flexible The different layers in the structure can be ‘joined’ together through bonding or packaging when it enters the waste tie-layers via an extrusion, co-extrusion or process or via extrusion or stream. This is intended to help extrusion lamination processes. build understanding with packaging Phase 2 guidelines 7 specifiers and designers on how the The focus is on polyolefin-based flexible packaging that is not currently A pack can only be considered recyclable in a given country/market if there is a realistic Recycled packaging they design is managed at widely sorted or recycled and therefore cannot yet be regarded as being, Recyclable materials chance (> 50%) that it will be (i) collected; (ii) sorted into a material fraction that is recycled in its end-of-life and take actions at the or not being, ‘Designed for Recyclability’. to a new material/product at scale and for which (iii) there are viable end market applications. design stage to optimise collection, Testing is needed to better understand if/how these types of flexible sorting and recycling possibilities. packaging can be sorted and/or mechanically recycled10 This includes when the recycled material is used in conjunction with virgin or recycled As the requirements for new sorting and recycling technologies such as materials from other sources (i.e. it does not only need to be used at 100% inclusion). 8 chemical recycling of polymers become better understood and available, Next steps these requirements will be integrated into the guidelines The key test of recyclability is whether the recycled materials will replace the need for new Design changes may be needed to enable these structures to be regarded material from virgin or recycled sources.12 as ‘Designed for Recyclability’ If the structures cannot be regarded as ‘Designed for Recyclability’ then it may be necessary to ensure these structures do not ‘disrupt’ the sorting 9 and recycling streams by ensuring that they can be easily identified and Appendices separated from the other ‘Designed for Recyclability’ structures HDPE High density polyethylene PET Polyethylene terephthalate LDPE Low-density polyethylene PO Polyolefin The scope also includes all flexible packaging structures other than those LLDPE Linear low-density polyethylene PP Polypropylene polyolefin-based structures (for example aluminium-based, paper-based, MRF Materials Recovery Facility PS Polystyrene other polymers, etc.) MSW Municipal solid waste PVC Polyvinyl Chloride NIR Near-Infrared RDF Refuse derived fuel PA Polyamide SRF Solid recovered fuel It is the intention to conduct a periodic review process (expected to be on an PE Polyethylene annual basis) for the CEFLEX guidelines to capture any changes in capabilities and requirements of emerging sorting and recycling technologies.

What is not possible today, might well be common practice tomorrow.

10 A programme of testing for Phase 2 will commence in 2020 with guidelines produced towards the end of 2020/start of 2021. Section 5 identifies where phase 2 testing is 11 See Appendix 1 for definition of multi-layer. needed and in Section 6 this is noted where relevant. 12 Derived from ISO 14021: 2016 Environmental labels and declarations 14 15

1 Introduction Methodology 4 Building understanding The guidelines have been developed The phase 1 guidelines identified and evaluated flexible packaging structures of the end-of-life 2 by stakeholders participating in the currently placed on the market based upon: Designing CEFLEX initiative and representatives for a circular from across the value chain including: y ili economy bilit lab ty processes for flexible Raw material producers ta yc Ink, coating and adhesive suppliers r c o e Film producers S R packaging Packaging converters 3 Purpose Brand owners and approach companies Recyclers Extended producer responsibility Sortability: an assessment of whether Recyclability: an assessment organisations the structure can be identified and of whether the structure can be Technology/machine suppliers. Packaging disposal 4 sorted into an appropriate material mechanically recycled using standard End-of-life stream using current technologies processes and technologies for Each part of the value chain has processes and processes in an industrial scale polyolefin-based materials, on an Once a product contained in flexible materials, then these parts should provided their input and expertise Separating different sorting facility industrial scale packaging has been used or consumed be easy to separate. However, the to ensure the guidelines encompass and the packaging no longer has a materials before ideal design would not require the the views of, and challenges faced by purpose, the consumer must be able consumer to separate parts and all. The content of the guidelines is 5 to easily identify how to dispose of it disposal incompatible materials should be based on value chain consensus, using The polyolefin-based structures that were evaluated as being able to be sorted Phase 1 in the correct collection receptacle, avoided wherever possible. the best available data from testing and recycled are regarded as being ‘Designed for Recyclability’ and within the guidelines so it is made available for sorting Other considerations include whether and commercial practices. This has scope of this document. and recycling. Examples of this are different parts of a pack such as film Providing clear instructions to considered the ‘best in class’ current the yellow bin in several European , labels, zips, caps and spouts etc. consumers on how to dispose of the technologies and processes available to This does not necessarily mean the packaging will be recycled but that if the countries. This is a key stage in ensuring should be separated. If the materials packaging after use is key. This is clearly collect, sort and mechanically recycle collection and sorting infrastructure exists it is likely to be able to be recycled. are compatible, then the different 6 the packaging materials are made dependent on the different systems and polyolefin-based post-consumer D4ACE available after use to be sorted and parts of the pack should remain infrastructure developed in different flexible packaging that are already in In addition, in some European regions, some flexible packaging structures not principles recycled. together. If the pack contains different regions and countries. operation at scale in Europe. within the scope of the first phase of the guidelines will be collected, sorted and recycled and used in a variety of end applications.

7 Recycled Emptyability materials When a consumer has used or Project Barrier consumed a product it is important that the pack can be fully emptied. The At the start of this process, CEFLEX used the work of the New Plastics Economy ‘Project Barrier’ pioneer project on ‘emptyability’ of a pack means that 8 recyclability guidelines for plastic-based flexible barrier packaging to inform the development of ‘Designing for a the consumer can easily remove the Next steps Circular Economy’. There is clear alignment between the two sets of guidelines, though with some differences in product with only a minimal amount scope, specific criteria and thresholds. (ideally none) of product remaining on or in the packaging. This reduces 13 The objective of Project Barrier was also to develop ‘design for recyclability’ guidelines for plastic-based flexible the level of residual product waste barrier packaging, focusing on post-consumer household flexibles, with the aim of influencing the design of packaging (for example food waste, detergents, put on the market and, in turn, the quality of materials entering the recycling streams. 9 personal care products) being present Appendices in the recycling stream and there will CEFLEX used this work as a starting point and incorporated input and expertise from each part of the value chain be less contamination to be removed to ensure the guidelines encompass the views of, and challenges faced by all. The content is based on value chain during the recycling process. Removal consensus, using the best available data from testing and commercial practices. of residual product waste adds cost to the recycling process and can impact the quality of the recycled material.

13 https://www.newplasticseconomy.org/projects/pioneer 16 17

1 Figure 3 Introduction Collection Sortability Sorting process for packaging waste Collection is the key step in developing the circular Sorting facilities also called Materials 2 Recovery Facilities (MRF) use a series Designing of processing steps to identify and economy for flexible packaging and must include Receiving Conveyor for a circular segregate the mix of materials into economy materials belt opener flexible packaging disposed of at both consumers’ separate fractions for recycling. homes and out of home or on the go. 1 2 3 The sorting processes exploit the different sizes, shapes and material 3 properties of the recyclables to identify Purpose CEFLEX calls for the establishment ensure that flexible packaging used out and segregate materials. Most MRFs Over belt Wind and approach of the infrastructure and systems to of home and on the go can be captured in Europe use automated processes magnet shifter screen enable all post-consumer flexible and made available for sorting and although some have operators to packaging to be collected for sorting recycling. Collecting and sorting on manually identify, pick and segregate 6 5 4 and recycling. This means collection the go packaging is important for specific packaging formats and 4 of all packaging (including flexible some formats, as this can represent material fractions. End-of-life packaging); and for this packaging to as much as 50% of the number of processes be separately collected from residual units entering the waste stream and Eddy Ballistic 3D The typical key sorting steps are shown and organic waste. can help contribute to the prevention current separation NIR in Figure 3. Individual sorting facilities 2D of littering. may have different configurations of 7 8 9 There are a variety of options for how processes and equipment. 5 this collection infrastructure can be There will also be some circumstances Phase 1 operated, for example a comingled where alternative collection systems Once the different fractions of guidelines stream of packaging including rigid will be needed. For example, in some material have been separated, a plastics (, pots, tubs and trays), high-density population areas it baler is used to compact the loose Baling metals and potentially , or a single may not be possible or practical for sorted material fractions, reducing stream of plastics. additional collection receptacles to be 10 the overall volume and transportation used and thus recyclable packaging will 6 costs. Each sorted fraction will have a D4ACE It is not considered good practice remain in the residual waste stream. technical bale specification detailing principles to collect glass with the other dry the characteristics and quality of the recyclables due to the impact it has In these situations, there is an material required by the recycler, on the sorting equipment in the next opportunity to use technologies including factors such as minimum stage of the process. and processes that enable flexible DRUM OR TROMMEL SCREEN: this is a rotating MAGNETIC AND EDDY CURRENT SEPARATION: OPTICAL SORTING: a range of different plastics purity level, maximum humidity cylinder that uses the size of the packaging these pieces of equipment are used to are used in packaging including PE, PP and packaging to be post-segregated 7 content, minimum and maximum to separate larger ‘oversized’ items from separate ferrous and non-ferrous metals. PET, etc. Optical sorting systems such as Recycled CEFLEX recognises that the choice from the residual waste stream prior smaller ‘undersized’ particles. Smaller items Over-band magnets are used to separate Near-Infrared (NIR) can be used to identify bale density, acceptable levels of materials of collection system is best made at to incineration/disposal and for it to and dirt will fall through the holes of the ferrous metals such as steel, whilst packaging and separate specific polymer types and contaminants, any contaminants not screen and typically this material will be containing aluminium foil can be separated material combinations. The NIR sorter the local, regional or national level be made available for sorting and acceptable at any level, bale wire and classed as a residual fraction which is not sent by an eddy current separator, which uses a uses a camera calibrated to identify the to provide a degree of flexibility and recycling. This is also the case for for mechanical recycling. Larger items will high-speed magnetic rotor to generate an individual polymer types. However, as the bale size. to enable specific requirements to be packaging consumed on the go and continue through the subsequent processing electrical current. This produces a magnetic camera can normally only see the plastic steps. As a significant proportion of flexible field which repels non-ferrous metals. layer on the top surface of the packaging, met. Collection should occur primarily packaging not disposed of in household packaging is smaller in size it is important Flexible packaging that contains aluminium in a multi-material flexible pack the NIR 8 at the household level but also needs to waste collection systems. that the screen size enables a good yield of foil (above a thickness of 5 microns) can will typically only see the outer layer and Next steps flexible packaging to be sorted for recycling. theoretically be detected by eddy current miss inner layers of potentially different Whilst 70mm and 50mm holes in a trommel separation technology, irrespective of the materials. Each optical sorting station can screen are commonly used, the current trend percentage of other materials in the structure. sort one or maximally two different materials and recommended screen size on new sorting The capability of an eddy current separator or colours. NIR optical sorting is usually a facilities in Germany is circa 20mm. to efficiently eject the packaging containing compromise between quality and yield; if aluminium foil depends on the configuration the NIR detector is programmed to reach BALLISTIC SEPARATION: a ballistic separator of the machine, in particular the number maximum output quality this will be achieved 9 uses the shape and the ability of a packaging of magnetic poles. For an infeed of waste at the expense of yield. Appendices item to bounce to classify items as two- containing mainly smaller items, a higher dimensional (2D) or three-dimensional (3D). number of magnetic poles is recommended The ‘light’ or 2D fraction will consist of flat (24 or 32). The efficiency of the sorting is also and thin materials such as flexible packaging dependent on the ‘quality’ of the infeed Note: NIR and other identification sorting (pouches, bags, sachets, removable lids, stream; the more homogeneous (not mixing technologies are improving continuously and wrappers), paper and cardboard; these very big heavy items with very small light are being retrofitted to improve the quality materials are thrown upwards towards the items) and the more evenly distributed flow of the sorted fraction where this is needed. top of the machine. The ‘heavy’ or 3D fraction of material (not too crowded on the sorting Other developments include for example consists of bottles, cans, pots, tubs and trays. belt) the better. digital watermarking with Project HolyGrail For flexible packaging to be separated from 2.0 developing a technique to ‘tag’ plastic rigid packaging it needs to be flat and 2D in packaging so that the exact packaging shape/format when it arrives at the ballistic composition can be read from a database. separator. This separation of 2D from 3D Further work will be undertaken in phase 2 on formats is important as the grades of PE optical sorting. and PP used in flexible packaging have very different properties to those used in rigid packaging and should be kept separate. 18 19

1 Introduction Recyclability

Once different material types (paper, mechanical recycling infrastructure oxygen conditions. The hydrocarbon These guidelines will be updated Figure 4. Individual recycling facilities Each application will have a technical 2 metals, plastics) have been separated across Europe will be required to fraction is also recovered and is to consider these emerging may have more, or less, processes and specification, detailing the characteristics Designing into distinct fractions they can enter a manage and process the increasing currently used to generate energy. technologies as a more comprehensive different configurations of equipment. and quality of the material required such for a circular recycling process. volumes of materials as more regions understanding of their role, capabilities, as melt flow index, colour, odour, food economy and countries collect post-consumer Other advanced recycling technologies, environmental, financial and regulatory Some recyclers will sell plastic grade criteria, etc. flexible packaging for recycling. such as solvent-based recycling, are considerations is obtained. flake rather than extruding the The focus of these being developed and commercialised, flake to a pellet for use in end Further information will be provided The quality of the input material to the opening further opportunities to The key stages of a typical mechanical market applications. on the recycling processes for paper 3 guidelines is on Purpose recycling process has a significant impact improve the recyclability of flexible recycling process used for polyolefin- and aluminium in phase 2 of the and approach mechanical recycling on the associated costs and yields for packaging structures. based flexible packaging are shown in CEFLEX guidelines. processes, recognising the recycler. Cleaner, less contaminated (by product residue and/or non-target In parallel the development of other that these will be material) input material is preferred as types of processes and technologies this reduces the cost of washing and such as chemical recycling is gaining Figure 4 4 the primary route End-of-life subsequent processes and improves momentum and is likely to have an processes for recycling flexible both the yield and quality of material important role to play as we move obtained from the recycling process. towards a circular economy. The term packaging in the short chemical recycling covers a range of Flexible plastic mechanical recycling process While for plastics and paper a technologies including pyrolysis, to medium term. mechanical recycling process gasification and depolymerisation. For 5 is currently used, for structures example, a pyrolysis process followed Feeder/ Conveyor Phase 1 Mechanical recycling processes for guidelines containing aluminium the process will by steps to recycle the hydrocarbons shredder belt flexible polyolefin-based materials generally start with pyrolysis to recover back into a Naphtha can be used are already proven and operated on the aluminium fraction by ‘removing’ to produce new plastics and other 1 2 a commercial scale in some European the plastic and other non-aluminium chemicals replacing virgin Naphtha. countries. Significant expansion of the materials at high temperature/low 6 D4ACE Wind Metal principles NIR shifter separation 5 4 3

7 Recycled materials Washing/ Grinders density separation Drying 6 7 8

8 Next steps Extrusion line 9

9 Appendices

SORTING: it is common practice for most recycling facilities to perform DENSITY SEPARATION: This process is used to separate polyolefins from some degree of additional sorting processes on the unbaled materials other plastics such as PET, polyvinyl chloride (PVC) or polystyrene (PS). which can include magnetic separation, eddy current separation and Polyolefins have a density of < 1g/cm3 (unless heavily filled) and will NIR optical sorting stations. float in the process, whereas the non-polyolefins have a density of > 1g/cm3 and will sink (unless expanded). SIZE REDUCTION AND WASHING: the waste plastics are typically size reduced i.e. shredded and washed in order to remove contaminants DRYING AND EXTRUSION: the final stage is drying and extrusion, where such as paper, residual food/product waste, dirt and sand. The more the plastics are melted, filtered and pelletised. contaminated the flexible packaging is the higher the costs of washing and the lower the yield of recyclable material generated. 20 21

1 Table 1: Phase 1 Designed for Recyclability flexible packaging structures14 Introduction 5 Phase 1 Designing Structures Notes

Mono-PE and mono-PP structures for a Circular Economy Technologies exist to sort and recycle 2 (should be a minimum of 90% PE or PP) Designing PE/PE and PP/PP laminate structures for a circular Technologies exist to sort and recycle economy Guidelines (should be a minimum of 90% PE or PP) PE/PP (mixed PO) laminate structures Technologies exist to sort and recycle (should be a minimum of 90% PO materials)15

3 PE and PP structures with coatings and layers Purpose Technologies exist to sort and recycle and approach such as EVOH, PVOH, Acrylic, SiOx and AlOx Mono-PET flexible packaging structures PE and PP structures with laminated and printed such as mono-PET lidding attached to Technologies exist to sort and recycle metallisation a mono-PET tray can also regarded as being ‘Designed for Recyclability’. Technologies exist to sort and recycle aluminium-based 4 End-of-life Aluminium-based structures structures where aluminium is the dominant material. Further processes The use of the term ‘mono-material’ details and explanations to be provided in phase 2 in this document is referring to what is considered ‘mono’ from a plastics Technologies exist to sort and recycle paper-based structures recycling perspective. CEFLEX Paper-based structures where paper is the dominant material. Further details and acknowledges this may be different explanations to be provided in phase 2 5 to what a packaging designer or Phase 1 guidelines technologist would consider to be a mono-material. The 90% by weight of mono-PE or mono-PP accepts there Table 2: Phase 2 flexible packaging structures will be up to a maximum of 10% other materials or elements included in the Structures Notes 6 flexible packaging structure. D4ACE PET laminate structures e.g. PET/PE, metallised PET/ principles Further investigation required to evaluate sortability and recyclability The list of flexible packaging structures PE, PET/PP etc. that have been assessed as being PA laminate structures e.g. PA/PE etc. Further investigation required to evaluate sortability and recyclability ‘Designed for Recyclability’ are shown in Table 1 (refer to definitions PE/PP (mixed PO) laminate structures16 Further investigation required to evaluate sortability and recyclability 7 in Appendix 1 for each polymer). The Recycled Structures containing PVDC Further investigation required to evaluate sortability and recyclability materials limits/percentages included in Section 6 should be taken into consideration Other mixed plastic laminate structures Further investigation required to evaluate sortability and recyclability with this table. Regarded as ‘Designed for Recyclability’ for structures with Those structures not covered in this Aluminium-based structures aluminium as dominant material as technologies exist to sort and 8 The scope of phase 1 of the CEFLEX guidelines document will be tested and covered recycle. Further details and explanations to be provided in phase 2 Next steps in phase 2 of the guidelines and are Further investigation required to evaluate sortability and recyclability is those polyolefin-based primary and secondary shown in Table 2. In addition there are Structures containing aluminium foil flexible packaging structures that can be regarded some structures (shown in Table 2) that Surface metallised structures Further investigation required to evaluate sortability are already covered by this document, as ‘Designed for Recyclability’ today; mono-PE, however, further work is needed to Regarded as ‘Designed for Recyclability’ for structures with paper as dominant material as technologies exist to sort and recycle. Further 9 better understand the impacts of these. Paper-based structures Appendices mono-PP and mixed polyolefin structures. If required, revisions will be made to details and explanations to be provided in phase 2 the phase 1 guidelines. Other paper structures Further investigation required to evaluate sortability and recyclability

If these structures are collected and Structures where aluminium and paper Other mixed material laminate structures Further investigation required to evaluate sortability and recyclability made available for sorting and recycling are the dominant materials are regarded Other elements within flexible packaging (where the infrastructure exists) as being ‘Designed for Recyclability’ in Further investigation required to evaluate impact on sortability structures e.g. tie layers, additives, adhesives, inks, then there is a realistic chance of the the same way as mono-PE, mono- and recyclability materials being mechanically recycled. PP and mixed PO structures. Further coatings, varnishes, barrier coatings, etc work is needed to fully understand In addition, structures containing paper how other paper-based structures and and aluminium have been referred to structures containing aluminium can within these guidelines where there be designed for recyclability which will 14 Refer to pages 27 and 28 for further information on thresholds for mono-PE, mono-PP and mixed polyolefin structures. is existing knowledge about their be conducted in phase 2. 15 Refer to pages 27 and 28 for further information. sortability and recyclability. 16 Refer to pages 27 and 28 for further information. 22 23

1 Figure 5 Introduction 6 Circular economy flexible packaging Preference for plastic recycling streams from 2 Designing for a circular post-consumer polyolefin-based flexible packaging economy design principles

3 Flexible mono-PE Flexible mono-PP Purpose PE and approach Stream already exists in some European countries Stream is either being developed or under PP with some market applications established. consideration in Europe. General design principles In future this stream may develop further to include Expectation that a range of viable non-food contact sub-streams for example recycled PE film natural, market applications, including film, will be developed. recycled PE film coloured. 4 End-of-life Flexible packaging includes a wide This is required to keep as much again with the opportunity to reduce processes range of different formats and financial value in the recycled the use of virgin plastics. There are elements, with each structure and materials as possible whilst realising also opportunities to replace other combination of elements designed the greatest environmental benefit. A materials, for example in wood plastic to meet specific packaging key objective when designing flexible composite applications. PO Flexible mixed PO functionalities, for example a certain packaging for a circular economy is to Stream already exists in some European countries with market applications established. 5 produce packaging that is as high up Phase 1 requirement for gas and moisture There is also the opportunity to guidelines barrier, resistance, stiffness, etc. the preferences outlined in Figure 5 produce energy (Solid Recovered Even with these specific functionality as possible. Fuel (SRF) and Refuse Derived Fuel requirements there are some generic (RDF)) especially from the smaller sized design principles that can be followed Within these plastic recycling stream or residue fractions that cannot be Mixed to support designing flexible packaging preferences, market applications and (mechanically) recycled for example Mixed plastics including flexibles 6 plastics This stream should only be produced where the above streams are not achievable and should be directed to for a circular economy. uses for the recycled materials can through pyrolysis. This is classified as D4ACE highest value end market application available. principles also be listed in order of preference. recovery, not recycling. The guidance included in the following This recognises that a range of sections relates primarily to plastic- market applications and products based flexible packaging. will be needed for the increased volumes of recycled materials from 7 References/guidelines relating to flexible packaging. Recycled materials paper-based structures and those containing aluminium are given where These guidelines have not been there is an agreed understanding of written to produce recycled polyolefin the impact of the design of flexible materials suitable for a specific end packaging containing either paper or market application. The recycled 8 aluminium or both, on the sorting and materials produced by adhering to Next steps recycling processes. However, these these guidelines will be suitable to use materials will be covered in more detail in a range of applications. Higher value in phase 2 when the required testing applications such as film packaging has been completed. may require a higher threshold of mono-material and a lower amount 9 In order to achieve the of ‘other materials’ than proposed in Appendices CEFLEX vision, a preference these guidelines. Work to understand of recycling streams is this is in progress. required. CEFLEX advocates The preference is for recycled PE or PP firstly collection of all flexible to be used back in to film applications packaging, followed by sorting (film to film) as this will help to retain and recycling the polyolefin- the greatest financial value in the based mono-material streams material and to reduce the use of virgin plastics where it is appropriate to do so. (mono-PE and mono-PP), over polyolefin mixes, over mixed In addition, recycled plastic can be plastics (including flexibles), used in non-film applications (film to over mixed materials. rigid) including , 24 25

1 Figure 7 Introduction Guidelines for designing polyolefin-based flexible packaging for recyclability Examples of flexible packaging structures 2 Designing for a circular The following sections provide guidelines to support sortability is All the limits/percentages included in economy guidance on designing the respective not desirable. these guidelines should be considered ics st elements of a flexible packaging as a holistic set of requirements. la structure. When adopting and The decision to change the design of P PP 22% implementing the guidelines, the a packaging structure (assuming the The examples in Figure 7 are typical ating 3 design and specification process product protection requirement can compositions of flexible packaging co r ie Purpose r should not result in an increased use still be achieved) can influence the structures, to show how the limits/ r a AlOx 0.2% and approach of resources. For example, increasing efficiency with which the packaging percentages for the elements of a B the weight or thickness of a structure material can be processed. Factors structure work together. k simply to meet the recyclability limits/ including processing speed and the In percentages within this document or production of scrap material for A summary of the guidelines is provided Ink 2.8% 4 increasing the size of the packaging instance should therefore be taken in Appendix 3. ive es End-of-life item to achieve the size and shape into consideration. h d processes A Adhesive 3%

Figure 6 ics st la P PE 72% 5 Phase 1 guidelines Elements of a flexible packaging structure

ves si e 6 h nk d I

D4ACE A principles Ink 5% ty ts si en n m e g D i P ics st 7 la P Recycled s materials al ri te a M pe illers ha & f s s & Paper e 8 v s e i tic Next steps z t s i i la P d

S PE 25% d

Plastics A

k In Barrier coatings Ink 2% 9 & layers Appendices Aluminium ive es atures d lacque h fe n r d l a s A a s Adhesive 2% n k o n i i t ing , at i co g

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s i r r

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A e a

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a r L P ics st la P PE 68% 26 27

P 1 la st Introduction ic s POLYMER CHOICE

2 Designing Polyolefins for a circular Polyolefin-based structures designed for mechanical economy recycling of polyolefins could be: A single polymer type (a PE or a PP), for example a low-density polyethylene (LDPE) structure; including their copolymers, ethylene copolymers and propylene copolymers, polar and Thresholds for mono-PP structures 3 non-polar Purpose A combination of grades of a single polymer type (PE or PP), Compatible Limited Not compatible and approach for example a mix of different grades of LDPE and linear with PP or compatibility18 with PP or low-density polyethylene (LLDPE) mixed PO with PP or mixed PO A polyolefin-based structure with a combination of PE and mechanical mixed PO mechanical PP, including their copolymers, ethylene copolymers and recycling mechanical recycling 4 propylene copolymers, polar and non-polar. processes recycling processes End-of-life processes processes The use of the term ‘mono-material’ in this document is consistent with what is considered ‘mono’ from a plastics >90% PP 80-90% PP <80% PP recycling perspective. CEFLEX acknowledges this may be different to what a packaging designer or technologist Notes for mono-PP structures: 5 would consider to be a mono-material. The 90% by weight (i) A minimum of 90% PP by weight of the total packaging Phase 1 of mono-PE or mono-PP accepts that there will be up to a guidelines structure is needed for full compatibility with a PP maximum of 10% other materials or elements included in mechanical recycling process, in order to maintain the flexible packaging structure. the quality and value of the final recyclate. This is the guideline threshold to be strived for. These structures Thresholds for mono-PE structures are also considered to be compatible with a mixed PO 6 mechanical recycling process. D4ACE principles Compatible Limited Not compatible (ii) Structures with 80-90% PP by weight will be accepted with PE or compatibility17 with PE or but will be of limited compatibility in PP mechanical mixed PO with PE or mixed PO recycling processes. This limited compatibility also Material selection mechanical mixed PO mechanical applies to mixed PO mechanical recycling processes. recycling mechanical recycling (iii) Structures with less than 80% PP will likely affect the 7 The materials used in flexible inside layer is exposed and made visible a polyolefin-based recycling stream processes recycling processes overall yield of the respective PP or mixed PO mechanical Recycled during the use, disposal, collection or Paper-based structures: process and could negatively impact the materials packaging structures play a processes key role in determining the sorting process. Structures containing aluminium: recycled plastic quality and are thus considered to be eddy current separation technology >90% PE 80-90% PE <80% PE sortability and recyclability of incompatible. The layer detected by the NIR can works on structures containing (iv) For structures that combine PE and PP refer to thresholds the packaging. also be the second layer of the aluminium foil, so the aluminium for mixed polyolefin structures on page 28. packaging structure if the outer layer does not necessarily need to be Notes for mono-PE structures: 8 (i) A minimum of 90% PE by weight of the total packaging Next steps This includes influencing how the is transparent or translucent. on the outer layer of the structure structure is needed for full compatibility with a PE flexible packaging is identified and or even a dominant material (see Note: Bio-based PE and PP are considered chemically identical mechnical recycling process, in order to maintain disposed of by a consumer and how it is If the inside layer is the same material Sortability section on pages 16 and to fossil fuel derived PE and PP and therefore indistinguishable. the quality and value of the final recyclate. This is the managed in the post-consumer waste as the outer layer, then this is not an 17 for further information about Bio-based PE and PP will not cause any issues with a mechanical guideline threshold to be strived for. These structures stream. For example, a paper-based issue. However, if the inner layer of the detection of aluminium foil by eddy recycling process. flexible packaging structure should be pack is a different material to the outer current separation technology). are also considered to be compatible with a mixed PO 9 mechanical recycling process. Appendices collected and managed separately to a layer i.e. multi-material, then there plastic-based structure and be sorted is a possibility that it will be sorted This will improve the changes of the (ii) Structures with 80-90% PE by weight will be accepted into a paper stream for recycling. into an incompatible fraction and risk flexible packaging being correctly but will be of limited compatibility in PE mechanical Mixed polyolefin structures disrupting the recycling process at the identified and sorted using the recycling processes. This limited compatibility also The preferences described and shown in Figure 5 recognise The recycling stream that a pack is next step of the chain. processes outlined in the Sortability applies to mixed PO mechanical recycling processes. that mono-materials are preferred to mixed PO materials in sorted into should be determined by the section on pages 16 and 17. (iii) Structures with less than 80% PE will likely affect the flexible packaging structures. This is justified by the increase dominant material used in a structure. The NIR visible layer(s) of the flexible overall yield of the respective PE or mixed PO mechanical in potential end markets for which mono-materials can be However, in practice the sorted fraction packaging structure should be the Mono-material packaging is currently recycling process and could negatively impact the considered. A mono-PE or mono-PP material can be included (recycling stream) a flexible pack ends material fraction it is sorted into: preferable as these structures are recycled plastic quality and are thus considered to be in a mixed PO material stream without negative impacts, but up in is often determined by the surface Plastic-based structures: PE or PP for easier to recycle and should contribute incompatible. not vice versa as some end markets for mono-materials, for layer(s) seen by NIR optical sorters. This those respective recycling streams or to an improved quality, and therefore (iv) For structures that combine PE and PP refer to thresholds example blown or cast films, require higher quality mono-PE is normally the outer layer of a pack but a mixed polyolefin recycling stream; or value, of the recyclate generated. for mixed polyolefin structures on page 28. or mono-PP respectively. could also be the inside layer if there PET so any structures containing PET is a reasonable possibility that the can be identified and removed from 17 Limited compatibility refers to those materials that are not preferred within a recycling process but do not present a significant risk of disruption to the process. 18 Ibid. 28 29

P 1 la st Introduction ic s This preference for mono-materials will become increasingly PET It is thought that a certain amount of PA can be processed important as the quantities of flexible packaging being PET is not compatible with a PE, PP or mixed polyolefin and tolerated in the polyolefin mechanical recycling process, 2 collected, sorted and recycled increase and more end market mechanical recycling process. however it has not yet been possible to quantify the level Designing applications are developed. of PA in flexible packaging that may have an impact on the for a circular If PET is used in a PE, PP or mixed PO laminate then it should recyclability of mono-PE or mono-PP. economy Currently it is not widely possible to sort out a mixed PO ideally be on the outer surface of the packaging structure stream if the sorting operation seeks to sort out a mono-PE so it can be identified by NIR optical sorting and removed Further work will be undertaken in phase 2 to evaluate and for recycling. If a mixed PO structure is seen by an NIR as a PE as a disruptor to a PE, PP or mixed PO mechanical recycling agree a limit for PA in flexible packaging waste streams, due to a PE layer being seen, then the PP material within the process. as well as considering opportunities to sort and recycle 3 PO mix will be sorted into the mono-PE stream for recycling. structures containing PA. Purpose If the PET is within a middle layer of a PE or PP laminated and approach If the NIR sees the PP layer of the mixed PO structure, then structure it may be sorted out in the density separation it will not be sorted into the mono-PE stream for recycling process (depending on the proportion of PET to PE, PP or but be sorted with the mixed PO fraction (or with the mono- Other polymers mixed PO material). PP fraction when/where that stream exists). The sorting of It is recognised that other polymers are being developed out of specialist markets and may become more mainstream in mixed PO structures is not an issue if the sorting operation Note: the impact of flexible packaging laminated structures 4 consumer flexible packaging in the future. Whilst some of End-of-life is only targeting a mixed PO stream for recycling and not a containing PET in polyolefin-based mechanical recycling these materials are eminently recyclable, it will take some processes mono-PE or mono-PP stream. process will be assessed in greater detail in phase 2. time to develop sufficient volumes of post-consumer waste Due to this sorting dilemma, these guidelines have chosen to use materials where it warrants them being sorted out of the the same threshold of 90% for the mixed PO structures as the mixed stream into their own specific fraction. When specifying mono-PE and mono-PP structures. This is in order to moderate these materials in flexible packaging applications, precautions 5 any impact of these mixed materials on the mono-materials PVC need to be taken to ensure that they are clearly identifiable Phase 1 PVC is a plastic which is problematic when used within guidelines streams that CEFLEX believes are needed in the future to satisfy as non-PE or non-PP so that they can be readily sorted out enough end markets for these mechanically recycled materials. packaging because no recycling infrastructure for PVC of the mono-material streams/fractions thereby avoiding packaging exists in Europe today and also contaminates disruption to the polyolefin-based recycling processes. However, CEFLEX also recognises that mixed PO materials are other types of plastic which could otherwise be recycled. It mostly used in less demanding end market applications which can be found in various forms, such as film around vegetables 6 may be able to tolerate PE, PP and/or mixed PO materials where or in blister packs. D4ACE the PE, PP and/or combination of the PE and PP represents only principles 80-90% of the total packaging structure by weight. The tolerable PVC should not be used in flexible packaging structures. lower limit of 80% of the PE, PP and/or mixed PO material will be further explored in phase 2 and revised as necessary.

Thresholds for mixed PO structures 7 Biodegradable and compostable polymers Recycled Biodegradable and compostable polymers even at low levels materials Compatible Limited Not compatible are expected to cause disruption of the mechanical PE, PP 19 with mixed PO compatibility with mixed PO and mixed PO recycling processes and negatively affect the mechanical with mixed PO mechanical quality and value of final recyclate. They should not therefore recycling mechanical recycling be used in PE, PP or mixed PO structures intended to be processes recycling processes mechanically recycled. 8 processes Next steps These polymers should be used only for targeted applications >90% PO 80-90% PO <80% PO where the waste packaging is collected in an organic waste management system rather than a plastics mechanical Notes for mixed PO structures: recycling stream. This will help to ensure these polymers (i) A minimum of 90% mixed PO by weight of the total cannot contaminate the recycling of other materials and is 9 packaging structure is needed for ‘full compatibility to be composted under the required conditions. Appendices with a PO mechanical recycling process, in order to maintain the quality and value of the final recyclate and this is the threshold to be strived for. (ii) Structures with 80-90% mixed PO by weight will be (Polyamide) accepted but will be of limited compatibility in mixed There is a lack of robust trial data to understand and evaluate PO mechanical recycling processes. the impact of Nylon or Polyamide (PA) on the polyolefin (iii) Structures with less than 80% mixed PO will likely affect mechanical recycling process. Polyamide has a pivotal role the overall yield of the respective mixed PO mechanical to play in providing oxygen, aromas and a grease barrier as recycling process and could negatively impact the well as excellent general mechanical and specific puncture overall yields and/or recycled plastic quality and thus resistant properties for flexible packaging structures. It considered to be incompatible. also helps to reduce overall plastic consumption through down-gauging.

19 Ibid. 30 31

Ba 1 Pa rr Introduction p ie e r r s PAPER AND PAPER LABELS BARRIER LAYERS AND COATINGS

2 Designing Paper is a widely used flexible Whilst specialised paper recycling Barrier layers and coatings are an Ethylene vinyl alcohol (EVOH) is often for a circular used in multi-layer polyolefin-based economy packaging material and is generally mills can manage and separate a important element of many flexible recyclable with the paper fraction certain quantity of non-fibre materials packaging structures, providing structures or applied as a coating to consisting of other formats of paper. including plastic in the fraction, this is essential packaging functionality and give a gas barrier. It is found in varying that of packaging, removal and/ If paper properties are needed in the undesirable as it impacts the overall Paper in the plastic recycling process in most circumstances significantly thicknesses depending on the overall or substitution of it, or alleviating flexible packaging structure, then fibre yield and quality achieved from is a serious disruptor as it is most reduce overall use of materials structure and application. A maximum 3 potential negative impacts during Purpose it should represent the dominant the recycling process and the plastic often not possible to remove 100% of and resources. of 5% of EVOH of the total packaging recycling should be carefully and approach material by weight and be able to fraction needs to be managed (usually the fibres before extrusion and any structure is permitted. Quantities considered in order to mitigate the risk be identified as paper in the sorting as RDF). This increases the costs for the remaining fibres carbonise during the A barrier layer can be co-extruded above this are thought to result in of increased food waste. It is recognised process and be sorted into the paper recycler, although the plastic may have extrusion process negatively affecting into a material construction at low issues during reprocessing and impact that there are technical challenges and fraction for recycling. a value if sold to a plastics recycler. the recycled plastic quality. levels and coatings can be applied at the quality of the recyclate. solutions need to be developed in order even thinner levels, often less than Poly vinyl alcohol (PVOH) is a water- 4 to remove/substitute it. End-of-life a micrometre. Other barrier film soluble barrier material and is used processes materials are laminated as films into in specialist applications including Depending on the application, a structure using adhesive, as is the multi-layer polyolefin-based materials such as EVOH, SiOx and case with PA, PET and aluminium foil. structures and can be applied as a AlOx coatings etc, can be evaluated Alu coating. A maximum of 5% of PVOH m to determine if they are suitable in The choice of barrier material and of the total packaging structure is 5 i alternatives to PVDC and if so, would u coating, and the amount used, will permitted. Phase 1 m be preferred. Each material and each guidelines have an impact on the sortability and Silicon oxide (SiOX) and aluminium ALUMINIUM FOIL application should be reviewed on recyclability of packaging. In order to oxide (AlOx) are applied as very thin a case by case basis, considering take account of the product protection layer coatings to give additional Flexible packaging containing For sorted structures containing foil, the holistic recommendations and and functionality requirements, the use barrier properties. These are often aluminium foil can readily be sorted the recovery of the aluminium content guidelines in this document. at a nanometer level in a structure so 6 out of the packaging waste streams is possible via a pyrolysis process. of barrier materials and coatings will still be required in certain applications. would fall under the maximum of 5% D4ACE using eddy current sorting technology – It should be noted that the plastic Further work will be undertaken to principles Where possible, the use of these should each by weight of the total structure. see Sortability section on pages 16 proportion of the structure will not yet better understand the impact of PVDC 20 stay within the limits given for their Acrylic coatings are typically used and 17. This is typically done in the be recycled via this process . on the mechanical recycling process recyclability in these guidelines. to improve the surface of a material sorting process after the magnetic belt for polyolefins, solutions to overcome for , to improve sealability sorting although this varies by MRF and If a structure containing aluminium Note: Sorting and recycling a flexible any issues and whether opportunities The percentages of allowable barrier and seal integrity, and to prevent 7 depends on how much aluminium foil does reach the plastic recycling process packaging structure containing a layer exist to sort and recycle structures film materials in polyolefin-based scratching of the overall material. A Recycled is contained in the pack. it is normally removed during the of aluminium foil is different to sorting containing PVDC during phase 2. materials density separation process and can and recycling of a metallised flexible structures are given here where this maximum of 5% of acrylic coatings is currently permitted. For smaller formats, for example be recovered through applications such packaging structure. See Metallisation is widely accepted/tested. These tend to be materials that are applied at very chocolate foil portions, they are as a fuel for cement making. section on page 32. Note: In the development of the low levels via coatings or co-extrusions. Further work will be undertaken on all potentially directed into the fines phase 1 guidelines, it was realised Where guidance is not given, further of the above points in phase 2. fraction at the early sorting stage, that little fact-based trial work has 8 investigation will be carried out so an additional eddy current sorting been undertaken to understand Next steps in phase 2. station is needed, which is the case in and evaluate the impact of the an increasing number of state-of-the- different barrier systems listed However, where a barrier material PVDC art sorting facilities. here. This work will be carried is required, it is not considered PVDC as part of a multi-layer structure out and the 5% limits revisited in appropriate to increase the overall with polyolefins is considered to be a Laminated plastic-based structures phase 2. material requiring further investigation 9 containing a thin layer of aluminium weight or thickness of the material so Appendices due to the issues it could cause in foil, which is used for its high barrier that the percentage of barrier material mechanical recycling systems. function but is also undesirable in is reduced and is below the limits However, PVDC has certain beneficial the plastic recycling process, can be included in this document. uses in some circumstances. separated from plastic streams by using eddy current sorting technology. The use of the following barrier PVDC is used as a barrier in food The equipment needs to be set-up to layers and coatings for polyolefin- packaging and since the environmental recognise thin aluminium foil layers based structures is permitted within impact of food waste is higher than in the packaging structure enabling specific limits. this fraction to be identified and segregated.

20 Improved valorisation of pyrolysis products is recognised as an important opportunity, for example pyrolysis oil used as feedstock for food-grade polymers 32 33

B A ar dh 1 r es Introduction ie i r v s e s Metallisation Flexible packaging structures with Laminated and printed metallised Adhesives 2 metallisation are notably different to flexible packaging structures do not Designing structures containing aluminium foil. cause any sortability issues. The NIR Adhesives play an important role in process which can negatively affect for a circular is not affected as the reflective layer is economy combining different materials for the recyclate quality and block the Metallisation is a vapour deposition within a laminated structure and can customising packaging functionality screen filters on the extrusion line. process which deposits a very thin layer therefore not be seen. Metallisation to suit the product or the environment Note: In the development of the of aluminium on the surface of a plastic is not regarded as a disruptor to the where it will be used. Adhesives such as polyurethane, acrylic phase 1 guidelines, it was realised film. This thin layer has a thickness plastics mechanical recycling process or natural rubber latex adhesives, as 3 that little fact-based trial work has Purpose of approximately 0.02 – 0.5 micron as the layer of metallisation is too thin The total quantity of adhesives used well as non-PE or non-PP based tie- Further work will be undertaken been undertaken to understand and approach and provides a range of functional to be significant. should be below specific thresholds layers, are permitted to a maximum in phase 2 to explore the impact of and evaluate the impact of the properties including oxygen, moisture to prevent it negatively impacting of 5% by weight of the total structure. However, structures that have surface surface metallisation on sortability. An different adhesive systems listed and aroma barriers as well as light the recyclate quality. It is reported The limit is to optimise the quality of metallisation may result in sortability evaluation of whether optical effects here. This work will be carried protection. Metallisation can be a layer that adhesives can give rise to gel the recyclate and to avoid disruption issues depending on the level of (sparkles) in recyclate are as a result out and the 5% limit revisited in within a laminated structure or on the formations during the extrusion of the recycling process. 4 metallisation and printing due to of metallisation and the impact these phase 2. End-of-life surface of a packaging structure. processes the reflection disrupting NIR optical have on end use applications will also sorting processes. be undertaken. P igm e n 5 t Siz s Phase 1 e & guidelines s h Pigments a p

e Size, shape and construction Carbon black containing masterbatch pigments that do not contain carbon 6 is generally not permitted as a pigment black. Therefore, if black is required, D4ACE to plastic-based flexible packaging then NIR detectable pigments should principles The size, shape and construction of the and made available for the subsequent substrates as it is not recognisable be used. pack will determine how the packaging sorting and recycling processes. by the NIR optical sorting technology Low levels of pigments (of natural or behaves in a sorting facility. Further used in MRFs. This only applies to carbon black lighter colours), or none, are preferred details about how this influences If individual packs (or detachable masterbatch colourant and not to black to improve recyclate quality and value sortability is covered on pages 16 pieces of packs) are smaller than 20 x 20 this threshold to facilitate sortability, 7 There have been recent advances inks printed on flexible packaging, as this will enable lighter coloured and 17. mm then they are likely to fall through in order to avoid increased use Recycled in material technologies which now though further work will be undertaken recyclate to be produced which has a the holes in the screening equipment materials of resources. allow detectable black plastics to be to understand the impacts on inks higher value and can be used in a wider Trommel screen holes are commonly used to sort packaging materials. If this identified and sorted. This utilises in phase 2. range of applications and products. 50mm or 70mm in diameter, although happens, these packs/pack elements To aid the separation of flexible there is a trend to reduce this to 20mm will end up in the residual fraction that packaging from rigid packaging in new state-of-the-art facilities. Taking is typically sent for energy recovery (or formats such as bottles, pots, tubs and 8 this into account the pack dimensions is still landfilled in some countries). trays, the flexible packaging should be Next steps should ideally be greater than 20 x 20 mm. primarily flat and 2D in nature rather If an item is greater than 20 x 20 mm it However, these guidelines do not than 3D. Typical 2D formats include will be sorted into the ‘eject’ (or targeted) support increasing the size of individual pouches, bags, sachets, removable stream passing though the trommel packaging items to be greater than lids and wrappers.

9 Appendices De ns it y Density

For a polyolefin mechanical recycling be taken when using fillers as their process, the density of plastic-based presence can alter the density to be structures must be < 1g/cm3 to allow > 1g/cm3 resulting in a polyolefin being the polyolefin materials to be separated sorted into the non-polyolefin fraction. from the non-polyolefins. Care should 34 35

Addit Inks ive & 1 s la Introduction & c q

f u i l e l

r

e layers substituting those substrate and value and to avoid disruption of s

Additives and fillers r

s layers acting as barriers the mechanical recycling process. 2 Lighter colours of print are preferable However, criteria about maximum Designing Additives and fillers not specifically each other. If these multi-material as the colour of the final recycled printing ink percentage needs to be for a circular mentioned above are permitted but structures are mechanically recycled material will be lighter and able better specified, also considering economy their use should be at the minimum in a polyolefin-based stream in the to be used in a wider range of end scientific or technical evidence. level needed for achieving required absence of compatibilisers, there will be Substances of very high concern use applications. functionality. This includes thermal issues with processing and the recyclate (SVHC)21 are not permitted in order Note: In the development of the phase 1 guidelines, it was realised that little stabilisers, UV (ultraviolet) stabilisers, will have poor mechanical properties. to allow the recyclate to be suitable Lacquers and inks without PVC binders 3 fact-based trial work has been undertaken to understand and evaluate the nucleating agents, mineral and for the greatest range of end market are permitted, up to a maximum of 5% by Purpose impact of the different ink and lacquering systems listed here. This work will and approach polymer cavitating agents, antistatic Compatibilisers are made up of applications. weight of the total structure. This limit be carried out and the guidance revisited in phase 2. agents, impact modifiers, chemical at least two parts, with each part is in place to optimise recyclate quality blowing agents and tackifiers. interacting with one of the two or Oxo-degradability additives are not more components of the incompatible permitted to maintain the quality Foamed thermoplastic non-polyolefin mixture. The result is the minor and mechanical properties of the 4 L elastomers are not permitted in plastic- component of the mixture will be ab End-of-life final recyclate. e processes based structures due to their low dispersed within the major component ls density. These materials will be sorted and be bound to it. The more effective and recycled with the PE, PP or mixed the dispersion and compatibiliser, Note: In the development of the polyolefin fraction and have a negative the more homogeneous the resulting phase 1 guidelines, it was realised Labels impact on the final recyclate quality. blend will be and the recyclate will that little fact-based trial work has 5 have improved properties. been undertaken to understand Phase 1 As with inks and printing, labels include removable; either by the consumer guidelines Compatibilisers have a role to play and evaluate the impact of the important product information for the after use (not preferred) or during the in rendering polymer blends that Further work will be undertaken in different additives/fillers listed consumer. If labels are used on flexible recycling process through the washing are not compatible and/or miscible, phase 2 on the role of compatibilisers. here. This work will be carried packaging structures the material process; at present this should be via such as combinations of PE and PA, out and the guidance revisited type should ideally be the same as a cold wash process. the NIR as the identification material PE and PET, to be compatible with in phase 2. 6 the material used for the main body i.e. it should represent less than 30% of D4ACE of the packaging structure. If the is a different material to the each packaging face presented to the principles Inks & main body of the packaging structure NIR optical sorting equipment. Paper la If a different material is used, then the it should not be of a size where there is labels should not be used on packaging c q label should be designed to be easily a risk that the label material is seen by that will be recycled as a plastic. u

e

r

7 Inks and lacquers s Recycled materials d Printing of flexible packaging provides to the overall level of gassing during Ad ition al important product information to the extrusion process. f e the consumer, including ingredients, a

t

nutritional and allergy information Black ink layers printed on flexible u r

8 and of course marketing and brand packaging do not usually result in 100% Additional features e

Next steps information. Lacquers and varnishes coverage of the packaging, leaving recycling, have the potential to s also provide barrier properties, enough spaces for NIR reflection thus significantly improve the quality of the water resistance and scuff resistance. enabling optical sorting. High levels of recycled materials. However, these In terms of additional features such It is known that some additional There are a range of ink, lacquer and black ink coverage should be avoided technologies have currently been as zippers, spouts, closures, valves features such as large spouts/closures varnish types used and many different so NIR reflection is not disrupted. demonstrated to only be effective on and taps incorporated into flexible relative to the overall weight of the packaging structures the same flexible packaging item can cause items 9 printing technologies. surface printed flexible packaging. Appendices In general: Currently lamination printing (where guidelines as outlined above in terms to be sorted with a rigid packaging However, whilst essential, inks are The level of printing is a factor to the print is sandwiched between two of polymer choices and pigments apply. stream. However, it is not possible reported to negatively impact the final be considered, with minimal levels materials and not in contact with the From a recyclability point of view, it is to give general advice on this, so it is quality of the recyclate (unless they of print coverage preferred, again product) is often used in laminated preferred that the material type used is suggested testing is undertaken if in can be removed before the extrusion to optimise the quality and value of structures for barrier functionality the same as the primary pack material. any doubt. process) and are for the most part the recyclate and to allow greater (so the inks don’t come into direct thought to be responsible for the choice and freedom in terms of the contact with the product) as part of grey-green colour of recycled PE and colour of the final recyclate and end the total packaging design in order recycled PP. When inks are used at a use applications to protect the product. This might relatively high level of coverage, they De-inking technologies, whilst not change due to barrier functionalities have been reported to also contribute yet widely commercial in plastics also offered by coatings or printed

21 https://echa.europa.eu/candidate-list-table 36 37

1 Introduction 7 Use of recycled materials from flexible 2 Designing for a circular economy packaging

3 Purpose and approach

These guidelines have not been will be limited to non-food contact written to produce recycled polyolefin applications22. Work on developing 4 materials suitable for a specific end mechanical recycling processes that End-of-life market application. The recycled can be approved by EFSA is continuing. processes materials produced by adhering to these guidelines will be suitable to The value chain is also working on use in a range of applications. Higher commercialising chemical recycling value applications, for example film for all polyolefins. This plastic to 5 packaging may have higher level plastic recycling process renews the Phase 1 requirements and require a higher virgin polymer properties and can be guidelines threshold of mono-material and a used in food contact applications. lower amount of ‘other materials’ than Chemical recycling of plastics and proposed in these guidelines. other technologies will be included in more detail in phase 2 of the guidelines. 6 Designers/specifiers of flexible D4ACE packaging should consider if they principles can incorporate a quantity of recycled PE or PP from flexible packaging into CEFLEX expects to their packaging. see these emerging

7 For film applications, it is generally technologies playing an Recycled assumed that it is not yet possible to increasingly important, materials use 100% recycled PE (or recycled PP) but that lower levels of incorporation and complementary, are possible. Similarly, where recycled PE, recycled PP or recycled PO can role to mechanical be used in non-film applications it recycling as we move 8 should be encouraged to drive the Next steps development of end markets for towards a circular these materials. economy. It is recognised that more than 70% of consumer flexible packaging 9 applications are food related (direct Appendices or indirect contact). Currently, the European Food Safety Authority (EFSA) has not issued positive opinions for any flexible PE, PP or polyolefin mechanical recycling process for use in direct or indirect contact with food. This means that in the short to medium term, the use of recycled PE, recycled PP and recycled PO from flexible packaging

22 CEFLEX is undertaking work to better understand what applications can utilise recycled materials from flexible packaging and at what levels. 38 39

1 Introduction 8 Next steps

2 Designing for a circular economy Phase 2 guidelines Future proofing

3 Purpose and approach Not all the flexible packaging structures currently placed The CEFLEX guidelines will be reviewed on a regular basis. on the market can be considered to be ‘Designed for This is expected to be annually, but this has not yet been Recyclability’. These structures which make up about 20-30% formally agreed or the review process put in place to do this. of the overall flexible packaging on the European market tend 4 These reviews will consider developments across the flexible End-of-life to be multi-material structures. They are generally used for processes more demanding applications which require higher barrier packaging value chain, including new packaging materials and or physical properties and subsequently result in the use structures, as well as developments in the collection, sorting of more complex combinations of materials, barrier layers, and recycling processes, technologies and infrastructure. adhesives, etc.

5 CEFLEX is developing a testing programme to research and Phase 1 In this fast-changing environment, the guidelines evaluate how these structures can be sorted and recycled. The objectives of this programme are to; CEFLEX guidelines will be regularly Undertake testing to better understand if/how flexible packaging structures that are not currently widely sorted updated to ensure that relevant and/or mechanically recycled can be sorted and recycled 6 Undertake testing to understand the impact of different advancements and innovations are D4ACE principles elements of a flexible packaging structure on its sortability incorporated and that the guidelines and recyclability. This will include inks, lacquers, adhesives, tie layers, additives, sealants and coatings. reflect best practice in the flexible packaging value chain. This programme will produce robust, credible and 7 independent data to be used as the basis for the development Recycled materials of phase 2 of CEFLEX guidelines. The testing programme will commence in 2020.

In the interim, where these structures are required, they should be designed so that they are easily identifiable at 8 the MRF (sorting stage) so that they can be removed and Next steps prevent them disrupting the mono-material streams – see Sortability section on pages 16 and 17.

9 Appendices 40 41

1 Introduction In the context of this document, Designed for Recyclability is when packaging is designed for collection, 9 Appendices sorting and recycling, using end-of-life processes that are used commercially in at least one country in Europe, including where this collection, sorting and recycling infrastructure is not yet in place for the packaging to actually be recycled.

2 Note: ‘Designed for Recyclability’, ‘Designed for Recycling’, ‘Recycling Ready’ and ‘Recycle Ready’ are Designing interchangeably used and reflect the same meaning. for a circular economy The aim for CEFLEX is for post-consumer flexible packaging to go into an active recycling stream in each Designed for country. At this time, it is recognised that not all countries in Europe have a flexible packaging collection, Appendix 1: Definitions and terminology Recyclability sorting and recycling infrastructure. Designed for recyclability in one country can be different from (D4R, DfR) another; therefore, a packaging specifier should check good practice locally to be consistent. Claims 3 that a pack is designed for recyclability or recyclable in a country where the recycling infrastructure is Purpose not yet operating should be avoided. Designed for Recyclability or Recycle Ready are terms used to say and approach Term Definition the packaging design is moving in the right direction, but the end game is to be "recyclable" with the recycling infrastructure working in practice where the packaging is placed on the market. This definition Rolled aluminium with a thickness 5 - 200 microns. Thicknesses for flexible packaging applications are is a CEFLEX one used to build this guideline document and should not be used to make marketing claims generally below 50 microns. Aluminium foil is used in flexible packaging structures either as the major Aluminium foil (by any in the value chain). component (aluminium-based structures) or as a (barrier) layer within other material structures. 4 Note: Closed loop circularity (i.e. turning food contact packaging back into new food contact packaging) is End-of-life Aluminium Oxide Is a very high gas and moisture barrier thin coating (typically 1- 10nm) that can be applied onto flexible processes not possible in most cases due to limitations such as food contact approval. (AlOx) films and can be used as an alternative to EVOH, PVDC, metallisation etc. An eddy current separator uses a powerful magnetic field to separate non-ferrous metals from waste after In the context of this document, aluminium-based flexible packaging contains aluminium as the Eddy Current all ferrous metals have been removed previously by some arrangement of magnets. The device makes use predominant material with a percentage of aluminium (generally above 80%) highly dependent on the Aluminium-based Separation of eddy currents (a manifestation of electromagnetic induction occurring when a magnetic field is applied gauge of the aluminium foil base structure (the thinner the foil the lower the percentage in general). It 5 flexible packaging to a conductor) to affect the separation. Phase 1 must be noted that a lower percentage than 80% would not negatively influence the aluminium recycling guidelines process23. Note this is different to a metallised film. Ethylene Polymers derived from more than one species of ethylene monomer. By using a copolymer some of the copolymers properties of the material can be altered to enhance the material structure to suit an application.26 Chemical recycling of polymer waste is defined as any reprocessing technology that directly affects either the formulation of the polymeric material or the polymer itself and converts them into useful products A copolymer of ethylene and vinyl alcohol. It offers outstanding barrier to gases, such as oxygen, carbon Ethylene Vinyl like monomers, basic-chemicals, alternative fuels and other value-added materials.24 dioxide and nitrogen and has very high resistance to hydrocarbons and organic solvents. It is usually co- Chemical Alcohol (EVOH) 6 extruded but can be a laminated barrier layer or a coating in many food applications.27,28 D4ACE (feedstock) Additional note from the Ellen MacArthur Foundation: chemical recycling can be considered in-line principles recycling with a circular economy if the technology is used to create feedstock, that is then used to produce new Flexible packaging structures typically bend easily and can include bags, pouches, envelopes, sachets, materials. However, if these same processes are used for plastics to energy or plastics to fuel applications, removable lidding/liners and wraps. Flexible packaging structures can be single or multi-layered, using these activities cannot be considered as recycling (according to ISO) nor as part of a circular economy. a variety of materials including plastic film, paper, aluminium foil or any combination of these. The Flexible packaging construction may be plain, printed, coated and/or laminated. Flexible packaging is most commonly The application of a thin layer of a functional material onto a substrate. (CEFLEX definition) Coating used to protect fast moving consumer goods products such as confectionery, snack foods, frozen foods, 7 Recycled The application of different layers of polymer side-by-side in one extrusion process as a separate film, bakery, fresh produce, meat, dairy, pet food, processed foods, cosmetics, personal care, householder Coextrusion materials coating or lamination layer. detergents, beverage bottle/can wrappings, pharmaceuticals, medical and other technical products.

Compatibilisers are used to render polymer blends that are not compatible and/or miscible, such as Has a linear molecular structure, allowing for tighter packing of molecules, thus resulting in a denser 3 combinations of PE and PA, PE and PET, which very often occur in multi-material structures, to be material (relative density of 0.940 – 0.970 g/cm ). It is a stiff material which has good tensile strength and compatible with each other. Compatibilisers are made up of at least two parts, with each part interacting High Density heat resistance. It has poor clarity and can be recognised by its opaque appearance. It is used for retail 8 Compatibilisers with one of the two or more components of the incompatible mixture. The result is the minor component Polyethylene and food bags via film extrusion processes. It is strong with good moisture barrier and is often used to Next steps of the mixture will be dispersed within the major component and be bound to it. The more effective this (HDPE) impart moisture resistance. It can be used as an to give moisture and grease resistance dispersion and compatibiliser, the more homogeneous the resulting blend will be and the recyclate will to paper packaging materials. It has a high melting point which makes it suitable for boil-in-the bag 29 have improved properties. applications. As a film it is more difficult to heat seal than low density versions.

A copolymer is a polymer derived from more than one species of monomer (for example ethylene is a Several layers of materials, films, foils, paper and coatings being bonded via adhesives or extruded Copolymer monomer).25 Laminate polymer to form a new material with special properties. In a laminate, a minimum amount of each 9 material can be used to meet the demands of an application. Appendices The molecular structure differs from LDPE in that it lacks the long chain branching and has a narrower molecular weight distribution (it has a density of 0.912 – 0.928 g/cm3). It generally has superior properties Linear Low-Density to LDPE, such as higher physical strength, and higher temperature tolerance. Greater elongation, higher Polyethylene tear, tensile and impact strength, all allowing a stronger material to be produced with less material. (LLDPE) Typically, it is used for carrier bags, stretch films and heavy-duty sacking. It can also be used as a high- performance sealing film when in a metallocene-based resin.30

23 Flexible Packaging Europe 26 Ibid. 28 Derived from The Wiley Encyclopaedia of Packaging 29 Derived from PIRA: Packaging Materials (2nd edition) 24 https://www.chemicalrecyclingeurope.eu/about-chemical-recycling 27 Ibid. Technology (2nd edition) Aaron L Brody & Kenneth Diana Twede and Ron Goddard 25 Introduction to Polymers (2nd edition) RJ Young and PA Lovell S Marsh 30 Ibid. 42 43

1 The molecular structure is characterised by long side-branches that give the resin their combination of Near-Infrared is a region within infrared electromagnetic radiation. It is an often-used method of Introduction Near-Infrared (NIR) flexibility, clarity and ease of processing (it has a density of 0.915 – 0.939 g/cm3). It is a widely used film, spectroscopy method, employed for the sorting of plastics waste.36 used for everything from , to garment bags, carrier bags, garbage bags, stretch and shrink Low-density Within the context of this document, paper-based flexible packaging is flexible packaging that contains films as well as being used as a coating. It is tough, flexible and shock resistant and has a good barrier to Paper-based Polyethylene (LDPE) paper as a dominant material. Paper mills prefer to receive no plastic and paper , or ones water vapour, but many organic vapours and essential oils will permeate it rapidly. It is a poor gas barrier flexible packaging 2 where the plastic is easily separated.37 to oxygen and carbon dioxide so is often found coated or laminated with relevant gas barrier materials. It Designing 31 for a circular is often used as a heat seal medium as a coating or lamination in multi-layer structures. Within the context of this document, plastic-based flexible packaging is packaging that contains > 80% Plastic-based economy polymers. Within this context the definition of mono-material and thresholds for polyolefin-based Materials Recovery Plants where collected recyclable materials from households are sorted into different categories (for flexible packaging materials within these guidelines should be noted. Facility (MRF) example plastics, cardboard, metal, paper).32 Polyamide, also known as nylon, is used in packaging in a film format typically ranging from 15 – 9 Reprocessing, by means of a manufacturing process, of a used packaging material into a product, a Polyamide (PA) microns, which is then co-extruded or laminated with other film structures due to cost but also to give a 3 Material recycling component incorporated into a product, or a secondary (recycled) raw material; excluding energy (includes PA6, PA66, heat seal layer. It is often used in an orientated form known as OPA or BOPA or in a cast form known as Purpose recovery and the use of the product as a fuel.33 PA12, PA11, PA611, and approach PA612) CPA. It is used for its toughness and strength over a broad range of temperatures, has excellent puncture An operation aiming to recover plastics waste via mechanical processes, i.e. grinding, washing, resistance, grease resistance and barrier to gases, oil, fats and aromas.38 separating, drying, re-granulating and compounding, thus producing recyclates that can be converted Mechanical A polyolefin polymer based on ethylene. There are three main types used in film applications HDPE, LDPE into new plastics products, often substituting virgin plastics.34 recycling and LLDPE. It is valued for three main properties; toughness, heat-sealability and barrier to water and 4 Note: Paper and metals are also mechanically recycled. water vapour. It has a low coefficient of friction and little, if any, moisture absorption. It is a very low-cost End-of-life Polyethylene (PE) packaging resin and has low process energy costs as it has the lowest softening point of the packaging processes Metallisation is a vapour deposition process which deposits a very thin layer of aluminium on the surface plastics. It is formed of long chains of C H (ethylene) units. The molecules are long straggling chains with of a plastic film. This thin layer has a thickness of approximately 0.02- 0.5 microns and provides a range 2 4 Metallisation branches, tangled together in various ways to form the tough, transparent, heat sealable material. The of functional properties including oxygen, moisture and aroma barriers as well as light protection. molecular structure of the types (HDPE, LDPE, LLDPE) of polyethylene vary.39 Metallisation can be a layer within a laminated structure or on the surface of a packaging structure. This is a high clarity film with moderate gas barrier and tolerates fairly high temperatures (typically over 5 A mineral based additive used to improve the properties of a material. Fillers are most often used as a Polyethylene Phase 1 Mineral fillers 200°C), though these properties can all be improved by orientating, coating or copolymerising the film. substitute for more expensive binding agents. terephthalate (PET) guidelines (includes PET, PBT, It is often laminated with PE to give the seal properties needed for a film application or it can have a Contains predominantly one material type, either PE (LDPE, LLDPE, HDPE), PP, PET, aluminium, paper PEN, PEF, PTF, LCP, sealable coating applied to it. It is typically found as a 12 micron film and is valued for its good clarity, PC, PETG, PCT, PCTA) or other. aroma barrier and moderate moisture and oxygen barrier.40

For plastics, this should be seen to mean >90% of one polymer type as this is the upper threshold when Polyolefin (PO) Group of polymer thermoplastics consisting of only PP and PE.41 6 the other elements such as adhesives, additives and inks are included. D4ACE Polyolefin-based In the context of this document, polyolefin-based flexible packaging is packaging made up of more than principles The exception is if one of the minor components, for example paper, biodegradable plastics etc, will flexible packaging 90% polyolefin materials. Mono-material disrupt the plastic mechanical recycling process. A member of the polyolefin family of polymers, PP is a versatile material used for a wide range of Bi-axially oriented and non-oriented forms of the same base polymer are considered to be mono-material applications and its polymer structure can be tailored to meet diverse requirements. It has a very low as are PE and PP copolymers and homopolymers, as long as they have a neutral or positive effect on the density, excellent chemical resistance and good strength at low cost. It is often used for applications such 7 recycled stream. as microwave packs due to its high melt point and provides a good moisture barrier. It is often produced Recycled Polypropylene (PP) materials This definition applies equally to paper and aluminium foil flexible packaging although the actual as a film in the biaxially orientated form known as OPP (or sometimes BOPP). Some non-orientated PP is percentage may vary depending on the recycling process (to be confirmed in phase 2). used in packaging, primarily for twist-wrap. Orientation improves its low temperature durability making it ideal for freezer applications and grease barrier properties. It is an economical film used across a variety Contains more than one layer of material where a ‘layer’ is only considered if it is greater than 1 micron of food applications.42,43 thick (where no material type is >90% of PE, PP or PO (or >80% for aluminium))35. The different layers in the structure can be ‘joined’ together through adhesive bonding or tie-layers via an extrusion, Polyvinyl Chloride Is part of the vinyl-based family of polymers. It is most often used in construction (pipes, windows, doors), 8 44,45 Next steps co-extrusion or lamination process, or via extrusion coating or extrusion lamination processes. The (PVC) but sometimes used for non-food packaging. different layers can be copolymer blends and do not need to be a single material. Multi-layer Is a copolymer of vinylidene chloride/vinyl chloride and acrylates. It is often used in food and medical There is a difference between layers and depositions. The addition of lacquers, adhesives, coatings and applications. It has very good gas barrier properties and it is also a barrier to moisture, most flavours and other material deposition processes including metallisation where the layer of deposited material is in Polyvinylidene aromas, has good chemical resistance and is heat sealable. It has been widely used in hot water shrink the order of 20 nanometres to 10 microns does not change the definition of mono or multi-material. Chloride (PVDC) bag application for meat products, though lower cost polymers are increasingly being used for this. It 9 is usually used as a co-extrusion sandwiched between other materials in a very thin form, to reduce Note: not all multi-layer structures are multi-material structures and mono-materials can be multi-layered. Appendices costs.46,47 Contains more than one layer of material where no material type is > 90% and the other layers are made Waste material generated by households or by commercial, industrial or institutional facilities in their of different materials. The different layers in the structure can be ‘joined’ together through adhesive Post-consumer Multi-material role as end-users of the product, which can no longer be used for its intended purpose. This includes bonding or tie-layers via an extrusion, co-extrusion or lamination process or via extrusion coating or waste returns of material from the distribution chain.48 extrusion lamination processes.

31 Ibid. 36 https://www.plasticsrecyclers.eu/glossary 42 Derived from: Introduction to Polymers (2nd edition) 45 Derived from: PIRA: Packaging Materials (2nd edition) 32 https://www.plasticsrecyclers.eu/glossary 37 https://cepi.org/ RJ Young and PA Lovell Diana Twede and Ron Goddard 33 Ellen MacArthur Foundation definition 38 Derived from: PIRA: Packaging Materials (2nd edition) 43 Derived from: PIRA: Packaging Materials (2nd edition) 46 Derived from: Introduction to Polymers (2nd edition) 34 https://www.plasticsrecyclers.eu/glossary Diana Twede and Ron Goddard Diana Twede and Ron Goddard RJ Young and PA Lovell 35 Flexible Packaging Europe 39 Ibid. 44 Derived from: Introduction to Polymers (2nd edition) 47 Derived from: PIRA: Packaging Materials (2nd edition) 40 Ibid. RJ Young and PA Lovell Diana Twede and Ron Goddard 41 https://www.plasticsrecyclers.eu/glossary 48 Ibid. 44 45

1 Waste material diverted from the waste stream during a manufacturing process. Excluded is reutilisation Introduction Post-industrial (Pre- of materials such as rework, regrind or scrap generated in a process and capable of being reclaimed consumer) waste within the same process that generated it.49

A pack can only be considered recyclable in a given country/market if there is a realistic chance (> 50%) 2 it will be (i) collected; (ii) sorted into a material fraction that is actually sent to be recycled in to a new Designing material/product at scale and for which (iii) there are viable end market applications. This includes when Recyclable for a circular the recycled material is used in conjunction with virgin or recycled materials from other sources (i.e. it economy does not only need to be used at 100% inclusion). The key test of recyclability is whether the recycled materials will replace the need for new material from virgin or recycled sources.50

Proportion, by mass, of recycled material in a product or packaging. Only pre-consumer and post- Recycled content 3 consumer materials shall be considered as recycled content.51 Purpose and approach Material that has been reprocessed from recovered (reclaimed) material by means of a manufacturing Recycled material process and made into a final product or into a component for incorporation into a product.52

Is a fuel produced from various types of waste such as municipal solid waste (MSW), industrial waste or commercial waste. 4 End-of-life The World Business Council for Sustainable Development provides a definition: “Selected waste and processes by-products with recoverable calorific value can be used as fuels in a cement kiln, replacing a portion of conventional fossil fuels, like coal, if they meet strict specifications. Sometimes they can only be used after pre-processing to provide ‘tailor-made’ fuels for the cement process.” Refuse Derived Fuel (RDF) RDF consists largely of combustible components of such waste, as non-recyclable plastics (not including 5 PVC), paper, cardboard, labels, and other corrugated materials. These fractions are separated by different Phase 1 processing steps, such as screening, air classification, ballistic separation, separation of ferrous and guidelines non-ferrous materials, glass, stones and other foreign materials and shredding into a uniform grain size, or also pelletised in order to produce a homogeneous material which can be used as substitute for fossil fuels in, for example cement plants, lime plants, coal fired power plants or as reduction agent in steel furnaces. 6 D4ACE An extremely high gas and moisture barrier thin coating (typically 1-10nm) that can be applied to flexible Silicon Oxide (SiOx) principles films and can be used as an alternative to EVOH, PVDC, metallisation etc.

SRF are solid fuels prepared from non-hazardous waste to be utilised for energy recovery in incineration Solid Recovered or co-incineration plants and meeting the classification and specification requirements laid down in the Fuel (SRF) EN15359 European standard.53 7 Recycled Solvent-based recycling is a kind of material recycling suitable for thermoplastics. Solvent-based materials recycling is a solvation process, in which the plastic material to be recycled is treated with selectively active solvent(s) to provoke the physical separation of two or more polymers contained in material Solvent-based mixtures (for example multi-layer plastic films). The macromolecular structure remains intact, so there recycling is an insignificant degree of polymer degradation. After the solvation process, the dissolved polymers are in a liquid/viscous form (depending on the solvent concentration at every step) so they can be separated 8 from insoluble components by conventional cleaning processes. Finally, the solvent will be recovered and Next steps recirculated, leaving a recycled polymer with negligible solvent content (in the order of ppm).54

A material can be considered ‘sortable’ if it can be correctly identified by one or more of the commonly used material recognition systems in modern automated packaging sorting facilities, for example Sortability (CEFLEX magnetic, eddy current, Near-Infrared (NIR), at normal speeds of operation, for example a conveyor speed 9 definition) of > 3m/s. As size, shape and weight can influence sortability, the identification should be (i) independent Appendices of orientation (top/bottom/sides should give the same result); and (ii) allow the pack to be successfully ejected into the appropriate sorted fraction.

Process of classification of the mixed plastic waste in multi-material collection schemes; Sorting it consists of separating plastics from non-plastic content as well as plastic itself into different colours/ polymer categories.55

49 ISO 14021: 2016 Environmental labels and declarations 53 ERFO (European Recovered Fuel Organisation) 50 Derived from ISO 14021: 2016 Environmental labels and declarations 54 Definition provided by APK AG 51 ISO 14021: 2016 Environmental labels and declarations 55 https://www.plasticsrecyclers.eu/glossary 52 Ibid. 46 47

1 The following table is a top line overview and summarises the key materials used in flexible packaging structures, the barrier and other Introduction Appendix 2: Materials and their properties properties they provide and their typical uses. For more detailed information on each material type and suitability for a specific application please check with material suppliers.

2 Designing for a circular Material Description Types Moisture barrier Gas barrier Other properties Heat sealable? Uses economy Multiple applications across many areas often used as a sealing HDPE, LDPE, LLDPE Depending on grade, high tensile strength, high Polyolefin-based polymer, very layer. Combined with other materials to give the gas barrier PE including copolymers and GOOD POOR temperature tolerance, can be used in retort YES common use that PE lacks - for use in food, personal care, household, 3 homopolymers structures Purpose pharmaceutical. and approach PP, CPP, OPP, BOPP Depending on orientation - good tear, strong tensile, Used particularly in freezer applications, in combination with Polyolefin-based polymer, very PP including copolymers and GOOD POOR high gloss, low temperature durability, grease YES other materials for food, pharmaceutical, beauty, household, common use homopolymers barrier, can be used in retort structures applications.

Where a gas barrier is needed, for example powders, coffee, 4 Good aroma barrier, highly resistant to EVOH Thin barrier film or coating EVOH POOR EXCELLENT NO cheese, meat, etc used as a layer or coating combined with other End-of-life hydrocarbons, organic solvents processes polymer materials.

Cheese, meat, ready meals, ovenable applications, wet wipes, Typically found as a 12-micron Very good clarity, good aroma barrier and stiffness, personal care, household detergents. PET, PBT, PEN, PEF, PTF, LCP, PET film commonly used in many MODERATE MODERATE very good heat resistance (over 200°C), can be used NO* *combined with coatings and other polymers to make heat 5 PC, PETG, PCT, PCTA applications in retort structures sealable though PETG can be sealed against PET. Some PET Phase 1 copolymers have sealable properties and some PET can seal to guidelines other PET in the same family

Good grease barrier, puncture resistance, barrier Film / co-extruded layer which Cheese, meat, pharmaceuticals are some of the main applications. PA, OPA, BOPA, PA6, PA6/6, to gases, oils, fats and aromas. Good strength PA provides high barrier with very POOR VERY GOOD NO* PA12, PA11, PA611, C-PA, PA612 toughness, over a broad temperature range, can be *combined with coatings and other polymers to make heat good puncture resistance sealable. 6 used in retort structures D4ACE principles Very high barrier used in thin Meat, pharmaceuticals are typical applications. Mainly used as in PVDC PVDC GOOD VERY GOOD Good flavour, aroma barrier and chemical resistance YES layers/coatings combination with other materials.

Very high barrier used in thin Where high gas barrier is needed and applied to other material SiOx SiOx EXCELLENT EXCELLENT n/a NO coatings substrates. 7 Recycled Very high barrier used in thin Where high gas barrier is needed and applied to other material AlOx AlOx EXCELLENT EXCELLENT n/a NO materials coatings substrates.

Used to package dry goods such as agricultural chemicals and detergents which are added to water in the package where it PVOH Water soluble film PVOH POOR EXCELLENT Resists most chemicals YES dissolves. Used in disposable bags used for hospital laundries, 8 powder dyes and agrochemicals. It can also sometimes be used as Next steps a top coating without being declared in the specification.

Laminated and printed or Where high gas barrier is needed and applied to other material Metallisation Various application methods VERY GOOD VERY GOOD n/a NO surface metallisation substrates.

Typically, a coating EVA EVA n/a n/a To improve stretch, heat-sealability and cling YES Applied as a sealing layer on other materials to improve sealing. 9 or a co-extrusion Appendices Broaden sealing range and improve hot tack and Acrylic Usually in a coating form Acrylic n/a n/a YES Applied on PP films for dried goods applications etc. gloss and printability for holographic applications

Where very high barrier against gas and/or light is needed (for Dead-fold property, heat conductivity, heat example coffee, powders, pharmaceuticals, etc.) and/or for Al (Aluminium) Foil thickness 6 -50 micron Al aluminium foil ABSOLUTE ABSOLUTE resistance, push-through ability, can be used in NO retortable packs (for example wet pet food) (can be made sealable retort structures by applying coatings or laminating with sealable polymers).

Used laminated with polymers or coatings to give sealability, food Many grades at 10gsm to in Various types, bleached, contact, gas and moisture barrier, grease resistance and improved Paper excess of 250gsm depending virgin, recycled materials, with n/a n/a Good dead-fold property, easily printed NO printing characteristics. Applications include food, personal care, on application various finishes pharmaceuticals). 48 49

1 The following table summarises the Designing for a Circular Economy Guidelines for the key elements of a flexible packaging structure. Introduction Appendix 3: D4ACE phase 1 guidelines summary For each element, guidance is given in terms of compatibility with a PE or PP mechanical recycling process. Reasons are provided for the guidance, along with general design advice. The table also identifies the materials and elements to be investigated in phase 2. Please refer to Section 6 of this document for full details.

2 Designing for a circular Materials economy Guidance and components Reasons Advice Compatible with PE or PP Limited compatibility with for investigation Not compatible with PE or PP in phase 2 3 mechanical recycling PE or PP mechanical recycling mechanical recycling Purpose and approach Facilitates higher value recyclate. Materials may move towards being more compatible as technology and infrastructure evolve. It is recognised that the materials in the limited Foamed polymers alter the 4 PET layers compatibility and not density of the material and End-of-life Mono-PE and mono-PP including compatible columns have impacts the flotation sorting Impact of PET in polyolefin- processes a role to play in packaging co-extruded, orientated, co-polymers within mechanical recycling based mechanical recycling Co-extruded or laminated PE/PP (mixed PO) Non-PE and non-PP foamed polymer layers in some applications and plants. processes with or without barrier layers and coatings as should not be replaced if Laminated PE/PE or PP/PP with Biodegradable and indicated below PVC layers there is a negative impact or without barrier layers and coatings compostable materials on product protection PA are known to disrupt the (there is often a greater s as indicated below mechanical recycling of PE, PP, 5 l Biodegradable and compostable materials environmental impact in a mixed PO materials and should product waste than the Phase 1 i guidelines r be diverted from mechanical packaging).

e recycling collection streams

t a and should not be used in any packaging designed for

M Plastics mechanical recyclability

6 MATERIAL D4ACE COMPOSITION Greater than 90% PE 80-90% PE Less than 80% PE principles THRESHOLDS FOR MONO-PE AND Greater than 90% PP 80-90% PP Less than 80% PP Facilitates higher yields and Impact of material MONO-PP STRUCTURES - higher value recyclate composition

7 MATERIAL Recycled COMPOSITION Greater than 90% PO 80-90% PO Less than 80% PO materials THRESHOLDS FOR MIXED PO STRUCTURES*

If paper properties are needed in a flexible 8 packaging structure, then Next steps it should represent the dominant material by weight and be able to be identified as paper in the sorting process and be sorted into the paper Paper in the plastic fraction for recycling s l mechanical recycling process Although aluminium foil 9 a Paper i is a serious disruptor as any is not compatible with a Appendices r n/a n/a remaining fibres carbonise plastic mechanical recycling - e Aluminium

t Aluminium foil during the extrusion process process, these structures can

a negatively affecting the be identified and removed in M recycled plastic quality the sorting process by using Paper eddy current separation technology. Sorted structures containing aluminium foil can be recycled via a pyrolysis process although the plastic proportion will not yet be recycled via this type of process

* The information in this row of the table relates specifically to the material composition of mixed PO structures in relation to compatibility to PO mechanical recycling processes rather than compatibility with PE and PP mechanical recycling processes. 50 51

1 Introduction Guidance Materials and components Reasons Advice for investigation 2 Compatible with PE or PP Limited compatibility with Not compatible with PE or PP in phase 2 Designing for a circular mechanical recycling PE or PP mechanical recycling mechanical recycling economy

Barrier materials have a role Impact of barrier layers and to play in providing light- coatings above 5% of total 3 weight high-performance For each barrier layer and coating maximum Facilitates higher yields packaging structure weight Purpose s packaging in some r and higher value recyclate. and approach 5% of total packaging structure weight - For each barrier layer and coatings over 5% of applications and should e Materials may move i not be replaced if there is a PVDC coatings r AlOx, SiOx, EVOH, PVOH, Acrylic total packaging structure weight - To be determined towards being more

r negative impact on product a AlOx, SiOx, EVOH, PVOH, Acrylic compatible as technology

protection (there is often PA layers B and infrastructure evolve. Laminated and printed metallised layers a greater environmental impact in product waste than Surface metallised films 4 the packaging). End-of-life processes

Increasing material thickness Prevention and reduction to improve recyclability of the of packaging in all its forms packaging is not encouraged - 5 should always remain the MATERIAL THICKNESS The minimum viable amount of material should be used waste prevention and priority in design of flexible Phase 1 reduction should always be packaging. guidelines a priority.

e Waste sorting facilities use p screens to separate larger a ‘oversized’ items from Pack size should not be 6 h smaller ‘undersized’ items. increased to improve s

D4ACE PACK SIZE Above 20mm x 20mm Above 20mm x 20mm Below 20mm x 20mm Smaller items fall through recyclability; waste n/a

&

principles the holes of the screen and prevention and reduction

e the material will usually be should always be a priority.

z

i classed as a residual stream S and not be recycled.

7 Recycled The pack should be designed to leave as little amount of materials PRODUCT RESIDUE Low quantities of product residue Moderate quantities of product residue Large quantities of product residue product residue as possible - IN PACK to facilitate higher yield of recyclate.

8 Next steps Density separation is commonly used to separate

y polyolefins from other t materials. Polyolefins have i 3 s a density of < 1 g/cm and will < 1 g/cm3 < 1 g/cm3 > 1 g/cm3 - n/a n float in the process, whereas

e material with a density of

9 D > 1 g/cm3 will sink and not Appendices be included in the PO-based recycling process.

s e Polyurethane, acrylic or natural rubber latex v i adhesives, as well as non-PE or non-PP based s Facilitates higher quality Impact of adhesives on Above 5% of total packaging structure weight To be determined -

e tie-layers, are permitted to a maximum of 5% recyclate. recyclability

h

d by weight of the total packaging structure A 52 53

1 Introduction Guidance Materials and components Reasons Advice for investigation 2 Compatible with PE or PP Limited compatibility with Not compatible with PE or PP in phase 2 Designing for a circular mechanical recycling PE or PP mechanical recycling mechanical recycling economy

Facilitates higher value recyclate as more natural/ 3 lighter colour. Purpose The paler the polymer s and approach t colour the less cross colour contamination when being n If black is required, NIR e recycled. As plastics are

Clear, natural or paler colours Black and darker colours Carbon black containing masterbatch detectable pigments should n/a m recycled it is known that

be used.

g the colour becomes greyer i P over time. 4 Carbon black containing End-of-life masterbatch is not processes recognisable by NIR optical sorting technology.

5 Phase 1 Facilitates higher value guidelines recyclate. Materials may Fillers in non-PE and non-PP structures which move towards being more rs e Additives and fillers are permitted but usage modify the density to be < 1 g/cm3 compatible as technology l and infrastructure evolve. il f should be minimised. This includes thermal SVHC are not permitted to & stabilisers, UV (ultraviolet) stabilisers, Substances of very high concern (SVHC) allow the recyclate to be Impact of additives, fillers, tie

6 s nucleating agents, mineral and polymer To be determined suitable for the greatest - layers and compatibilisers on

D4ACE e range of end market sortability and recyclability

v cavitating agents, antistatic agents, impact Oxo-degradability additives

i applications

principles t

i modifiers, chemical blowing agents and

d Oxo-degradability additives d A tackifiers. Foamed thermoplastic non-polyolefin are not permitted to elastomers maintain the quality and mechanical properties of the final recyclate 7 Recycled materials

COLOUR Lighter, paler ink colours Darker ink colours n/a Facilitates higher value recyclate as more natural/ 8 paler colour and avoids Next steps s Impact of inks, lacquers and r disruption of mechanical varnishes on sortability and e recycling process. u Lacquers and inks (without PVC binders) recyclability q TYPE AND Lacquers and inks (without PVC binders) PVC binders are known to c up to a maximum 5% of total packaging Lacquers and inks containing PVC binders disrupt the recycling process.

a COVERAGE above 5% of total packaging structure weight l -

structure weight

&

s

9 k

n Appendices I Surface printing Impact of both printing PRINTING Facilitates higher quality methods and printing To be determined n/a SURFACE recyclate. surface on sortability and Lamination printing recyclability 54 55

1 Introduction Guidance Materials and components Reasons Advice for investigation 2 Compatible with PE or PP Limited compatibility with Not compatible with PE or PP in phase 2 Designing for a circular mechanical recycling PE or PP mechanical recycling mechanical recycling economy

3 Purpose s If the label is of a different material to the l Above 30% of the total surface area of the Ensures correct sorting and and approach e Same as the main material i.e. mono-PE or main material, then a maximum size of 30%

facilitates higher quality - n/a b pack if material is different to the main mono-PP of each packaging face and should be easily a material recyclate.

L removable

4 End-of-life processes

s re 5 u If the pack contains different materials, Phase 1 t a ZIPPERS, then these parts should be easy to separate. guidelines e f SPOUTS, The material type used is the same as the However, the ideal design should not require Facilitates higher yield of l CLOSURES, - n/a

a main pack material the consumer to separate parts and different recyclate.

n VALVES

o

i materials should be avoided wherever

t AND TAPS

i

d possible. d 6 A D4ACE principles

7 nt Recycled te materials n o The use of recycled content in flexible packaging to reduce the use of virgin material and create markets for recycled materials is encouraged. c

d Note: this is for non-food applications. For food contact and indirect food contact applications all materials must adhere to food safety regulations and at this time recycled materials from polyolefin-based

e

l flexible packaging are not approved as food safe.

c

y

c

e 8 R Next steps

9 Appendices ceflex.eu @MissionCircular [email protected]

The CEFLEX initiative would like to thank all the companies, organisations and individuals that contributed to the development of the Designing for a Circular Economy Guidelines.

PHOTO CREDITS Page 15: Courtesy of EXPRA Page 18: Tönsmeier Page 20: Courtesy of EXPRA Page 30: Assan Alüminyum Page 36-37: Cadel Deinking Page 39 (top image): Brückner Maschinenbau