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Home , Corrugated fiberboard, Paper recycling, Shive (papermaking), Wet strength

designdesign guidanceguidance forfor recyclabilityrecyclability a resource for -based packaging designers This is an interactive PDF; you can navigate to a by selecting it in the table of contents below. table of contents

introduction 3 16 methodology & scope 4 multiwall shipping sacks 17 molded fiber 18 how paper works 5 appendices 19 ease of recyclability 9 definitions of “recyclable” 19 , dyes, , tapes & 9 definitions of non-fiber elements 21 , barriers, metals & 10 insights from mills — foils 24 foils, & non-tree fibers 11 insights from mills ­— wet strength resins 25 recommendations by product type 12 recyclability standards and testing facilities 26 corrugated packaging 12 additional resources from other industry associations 34 bleached 13 endnotes 36 recycled/unbleached boxboard cartons 14 carrier stock cartons 15

Copyright © 2021, American Forest & Paper Association, All rights reserved Version 1.0, Last Update February 23, 2021 3 introduction

Paper-based packaging is recyclable. Some The findings in this report were the result of an AF&PA survey non-fiber elements that are applied to paper-based of member company mills in a range of sectors in the United packaging, like barrier coatings or adhesives, may States and Canada. create challenges for paper mills to recycle. With The technical guidance is not meant to be mandatory or a increased interest among consumer products standard for the packaging industry. companies to provide more recyclable packaging for While there are other uses for paper-based packaging in making their customers, the paper-based packaging industry new products other than paper and paperboard, the objective of recognizes the opportunity to bring clarity to how this report is to present research-based findings on the impact packaging gets recycled in paper mills and how various of various non-fiber elements frequently found on paper-based non-fiber elements affect the recyclability of paper- packaging on recyclability in paper mills. based packaging. AF&PA hopes that this guidance will prove to be useful to The American Forest & Paper Association (AF&PA) developed the members of the paper-based packaging manufacturing Design Guidance for Recyclability for Paper-based Packaging for supply chain ­­— consumer products companies that desire members of the paper-based packaging manufacturing supply more recyclable packaging, designers that specify it, and the chain to use in designing and manufacturing packaging to meet manufacturers and who make it — to better achieve customers’ needs in terms of recyclability. their goals. 4 scope methodology The following types of based packaging are included systems or leaves residue on recyclable paper-based in the study: finished paper or paperboard. packaging were identified as A survey was sent to AF&PA member l Adhesives (water soluble; hot- How much of a non-fiber the focus of the study: company mills in a range of sectors melt) element can make it a that use recovered paper grades l Corrugated packaging l Barriers (polymer; ) recycling “challenge”? It is l likely to include the various types of Bleached paperboard cartons l Coatings (clay; varnish; wax) highly dependent on each mill’s l l recyclable paper-based packaging Recycled/unbleached Dyes (water soluble) repulping capability. When asked l found in the Scope. A total of 65 boxboard cartons Foils (metalized; stamped; this question, fewer than half l surveys were sent to mills in the Carrier stock cartons laminated) of respondents provided data. l Kraft paper bags l Inks (water-based; UV EB) United States and Canada. Of those, For those that did, the numbers l Multiwall shipping sacks l Metals 49 completed surveys were returned, varied widely. For example, l Molded fiber containers l Non-tree fibers responses for the amount of one for a response rate of 75 percent. l Plastics Three other types of recyclable non-fiber element that presented l Polymer windows In total, data for 86 mills was paper-based packaging were l Pressure-sensitive labels a challenge ranged from “any reported. Those 86 mills represent targeted for the study, but the l Tapes (paper; polymer) amount” to “more than 20%”. 74 percent of the total amount research did not return enough l Wet strength resins of recovered fiber grades likely mill survey responses: l Wax NOTE: to include the types of recyclable l Paper cups Being a challenge does not make This report identifies non- paper-based packaging found in the l Aseptic cartons something not recyclable. It is fiber elements that may Scope that our members consume. l Gable-top cartons important to note that each non- become recycling “challenges”. The survey was conducted online fiber element applied to each kind The following kinds of non- Something becomes a challenge and with some follow-up interviews, of packaging was rated by some fiber elements frequently when it slows down a mill’s and was open between June 15 and mills as not a challenge. found on recyclable paper- pulping process, plugs screening June 30, 2020. 5 click here to download AF&PA’s how paper Process infographic recycling

works: FACT: Recycled paper fibers STEP 1: pulping and can be reused 5 to 7 times More than 90% of Americans have contaminant removal to make new products. 2 access to community paper and paperboard recycling.1 Paper is At the , recycled paper is fed into collected as part of municipal and commercial recycling systems at homes, large pulpers where it is mixed with water schools and businesses. Collection and agitated to release individual fibers. systems are tailored by type, such as Contaminants like staples, liners, residential and commercial. After the coatings, tape and adhesives are paper is collected, it is transferred separated and sent for disposal. The to a recycling center or Material remaining fiber is in a solution of 99% Recovery Facility (MRF). Recycled water and ready for papermaking. materials are sorted to remove , In 2019, the U.S. rate was plastics and metals, or even food . Paper is further sorted by type, 66.2% and the paper recycling rate has met baled and transported to paper mills or exceeded 63% for the last 11 years. where the recycling process begins. 6 how paper recycling works: STEP 2: and water FACT: More than 80% lay the foundation More than 90% of Americans have of all U.S. paper mills access to community paper and use some recovered The water-saturated pulp slurry, known as furnish, is a fiber.3 paperboard recycling.1 Paper is blend of fiber lengths that are optimized for the strength collected as part of municipal and and optical properties suited for each individual commercial recycling systems at homes, product. The papermaking process begins schools and businesses. Collection with a layer of furnish consisting of systems are tailored by type, such as 99% water and 1% pulped fiber that is residential and commercial. After the dispersed evenly over a continuously paper is collected, it is transferred moving wire screen. to a recycling center or Material Recovery Facility (MRF). Recycled materials are sorted to remove glass, plastics and metals, or even food waste. Paper is further sorted by type, baled and transported to paper mills where the recycling process begins. 7 how paper recycling STEP 3: additives go in, works: water comes out As the furnish moves through the More than 90% of Americans have machine, more and more water is access to community paper and removed, and paper is formed as paperboard recycling.1 Paper is it progresses through a series of collected as part of municipal and rollers and dryers. Water is reused commercial recycling systems at homes, throughout the process and the schools and businesses. Collection finished sheets contain about 8% systems are tailored by type, such as water, depending on the paper type. residential and commercial. After the Some coatings and additives, such as paper is collected, it is transferred , , and clay coatings, can be to a recycling center or Material Recovery Facility (MRF). Recycled added during the papermaking process to materials are sorted to remove glass, meet desired product qualities. plastics and metals, or even food waste. Paper is further sorted by type, FACT: North American paper mills would run baled and transported to paper mills out of fiber in about six months without the constant input of virgin fiber. 4 where the recycling process begins. 8 how paper a finely calibrated process

recycling Both the mill operations and the necessary feedstock are optimized for a particular works: range of recycled content, from zero to 100%. Altering the type of paper More than 90% of Americans have produced and the amount of recycled access to community paper and paperboard recycling.1 Paper is content it contains may require collected as part of municipal and substantial changes to operations commercial recycling systems at homes, and equipment, as well as expenses schools and businesses. Collection costing millions of dollars, each time a systems are tailored by type, such as switch is made to new equipment. residential and commercial. After the paper is collected, it is transferred to a recycling center or Material KEY TERMS: Recovery Facility (MRF). Recycled • Virgin pulp and paper mills: Mills that use predominantly (80% or materials are sorted to remove glass, more) fiber to manufacture new pulp, paper or paperboard. plastics and metals, or even food • Recycled mills: These pulp and paper mills use predominantly (80% or waste. Paper is further sorted by type, more) recovered paper in manufacturing. baled and transported to paper mills • Swing mills: These paper mills operate in the middle range, using where the recycling process begins. between 20-80% recovered paper in manufacturing. 9 ease of recyclability inks, dyes, adhesives, tapes & labels l This non-fiber element does not adversely recycled/ impact the recyclability of this item in mills. carrier stock bleached unbleached cartons multiwall l 33% or more of respondents rated this corrugated paperboard boxboard unbleached Kraft kraft paper shipping molded fiber non-fiber element as a challenge in mills. packaging cartons coated/uncoated paperboard bags sacks containers Being a challenge does not make something not recyclable. l This non-fiber element is typically not found on this product.

inks & dyes water-based inks l l l l l l l water soluble dyes l l l l l l l UV EB inks l l l l l l l adhesives water soluble adhesives l l l l l l l hot melt adhesives l l l l l l l tapes & labels paper tape l l l l l l l polymer tape l l l l l l l pressure sensitive labels l l l l l l l 10 ease of recyclability coatings, barriers, metals & plastics l This non-fiber element does not adversely recycled/ impact the recyclability of this item in mills. carrier stock bleached unbleached cartons multiwall l 33% or more of respondents rated this corrugated paperboard boxboard unbleached Kraft kraft paper shipping molded fiber non-fiber element as a challenge in mills. packaging cartons coated/uncoated paperboard bags sacks containers Being a challenge does not make something not recyclable. l This non-fiber element is typically not found on this product.

coatings & barriers clay coatings l l l l l l l varnish coatings l l l l l l l wax coatings l l l l l l l polymer barriers l l l l l l l bioplastic barriers l l l l l l l metals & plastics metals l l l l l l l plastics l l l l l l l polymer windows l l l l l l l 11 ease of recyclability foils, wet strength resins & non-tree fibers l This non-fiber element does not adversely recycled/ impact the recyclability of this item in mills. carrier stock bleached unbleached cartons multiwall l 33% or more of respondents rated this corrugated paperboard boxboard unbleached Kraft kraft paper shipping molded fiber non-fiber element as a challenge in mills. packaging cartons coated/uncoated paperboard bags sacks containers Being a challenge does not make something not recyclable. l This non-fiber element is typically not found on this product.

foils laminated foils * l l l l l l l stamped foils * l l l l l l l metallized foils * l l l l l l l other wet strength resins ** l l l l l l l non-tree fibers l l l l l l l

* This guide includes additional insights from mills on the recyclability of foils on page 24. ** This guide includes additional insights from mills on the recyclability of wet strength resins on page 26. 12

THE BOTTOM LINE: Easier to recycle • Water soluble inks, dyes and adhesives, UV EB inks, paper and l water-based inks polymer tapes, clay coatings and l water soluble dyes varnish cause few problems. l UV EB inks l water soluble adhesives l paper tape l polymer tape l pressure sensitive labels Recycling challenges corrugated l clay coatings l hot melt adhesives l varnish coatings l wax coatings packaging l polymer barriers l bioplastic barriers Corrugated packaging is strong, l polymer windows l metals convenient and sustainable. It is the l metalized foils l plastics single most recycled packaging material. l non-tree fibers l laminated foils In 2019, the U.S. recycling rate for l stamped foils corrugated packaging was 92%. Walls l wet strength resins of corrugated packaging consist of Definitions for non-fiber elements two parts: linerboard (or facing) on appear in the appendix. l 33% or more of respondents rated these the exterior and corrugated medium non-fiber elements as a challenge in mills. (fluted paper) between layers of facing. Being a challenge does not make some- thing not recyclable. Various layers can be used to increase the packaging’s strength. 13

THE BOTTOM LINE: • Water soluble inks, dyes and adhesives, clay coatings and UV EB inks are no problem. • Foils, wet strength resins and Easier to recycle polymer windows can create l water-based inks challenges. l water soluble dyes l UV EB inks bleached l water soluble adhesives l clay coatings Recycling challenges paperboard l varnish coatings l hot melt adhesives l polymer barriers cartons l polymer windows l metals l laminated foils Bleached paperboard is a premium l non-tree fibers l paperboard grade that is white in color. It stamped foils is an excellent packaging choice for food, l metalized foils cosmetics, pharmaceuticals and countless Definitions for non-fiber elements l wet strength resins other products. Clay increases appear in the appendix. l 33% or more of respondents rated these the printability of the ’s surface; non-fiber elements as a challenge in mills. other coatings can improve wet strength Being a challenge does not make some- protection. thing not recyclable. 14

THE BOTTOM LINE: • Water soluble inks, adhesives and dyes, UV EB inks, clay coatings and Easier to recycle varnish cause few problems. l water-based inks • Some mills are challenged by wet l water soluble dyes strength resins and foils. l UV EB inks l water soluble adhesives recycled/ l clay coatings unbleached l varnish coatings Recycling challenges l polymer barriers l hot melt adhesives boxboard l bioplastic barriers l laminated foils l metals l stamped foils cartons l plastics l metalized foils Boxboard designates the type of l polymer windows l wet strength resins paperboard used for making . l non-tree fibers l 33% or more of respondents rated these Recycled/unbleached boxboard cartons non-fiber elements as a challenge in mills. are highly versatile, offering superior Definitions for non-fiber elements Being a challenge does not make some- strength for protecting products such as appear in the appendix. thing not recyclable. cereal and food products, dry household and commercial products, gameboards and shoeboxes, etc. 15

Easier to recycle THE BOTTOM LINE: l water-based inks l water soluble dyes • Water soluble inks, adhesives and l UV EB inks dyes, UV EB inks and clay coatings l water soluble adhesives cause few problems. l clay coatings • Some mills are challenged by wet l varnish coatings strength resins, foils and hot melt l polymer barriers adhesives. l bioplastic barriers carrier stock l metals l plastics cartons l polymer windows Recycling challenges Kraft paperboard cartons that provide l non-tree fibers l hot melt adhesives superior product protection and maintain l laminated foils structural integrity when wet. They are the Definitions for non-fiber elements l stamped foils preferred choice for beer and soft drink appear in the appendix. l metalized foils multipacks, and other food and non-food l wet strength resins uses that require durability and excellent printability. l 33% or more of respondents rated these non-fiber elements as a challenge in mills. Being a challenge does not make some- thing not recyclable. 16

THE BOTTOM LINE: • Water soluble dyes, inks and UV EB inks are no problem. Easier to recycle • Water soluble adhesives, metals, l water-based inks plastics and non-tree fibers can be l water soluble dyes managed easily. l UV EB inks kraft paper l water soluble adhesives l varnish coatings bags l metals Recycling challenges l plastics The name Kraft comes from the German l hot melt adhesives l word meaning “strong”. And Kraft paper polymer windows l polymer barriers l bags are a popular choice due to their laminated foils l bioplastic barriers l superior strength as well as the versatility stamped foils l wet strength resins they offer in size and shape. They are l metalized foils l also an eco-friendly choice, being both l non-tree fibers 33% or more of respondents rated these non-fiber elements as a challenge in mills. biodegradable and 100% recyclable. Being a challenge does not make some- Definitions for non-fiber elements thing not recyclable. appear in the appendix. 17 THE BOTTOM LINE: • Consistent with other packaging types, water soluble dyes, both types of inks and water soluble adhesives are no problem. • Clay coatings, polymer barriers and Easier to recycle varnish are manageable. l water-based inks l water soluble dyes multiwall l UV EB inks Recycling challenges l water soluble adhesives l hot melt adhesives shipping l clay coatings l bioplastic barriers l varnish coatings l plastics sacks l polymer barriers l polymer windows l metals l Paper shipping sacks are used as laminated foils l packaging for a variety of bulk dry food, stamped foils agricultural and industrial materials. As Definitions for non-fiber elements l metalized foils appear in the appendix. a packaging material, multiwall shipping l non-tree fibers sacks are safe, durable, efficient and l 33% or more of respondents rated these economical. Paper shipping sacks also non-fiber elements as a challenge in mills. offer an excellent backdrop for print Being a challenge does not make some- graphics. thing not recyclable. 18

THE BOTTOM LINE: Easier to recycle • Consistent with other packaging types, water soluble dyes and both l water-based inks types of inks are no problem. l water soluble dyes l UV EB inks • Foils and wet strength resins are l water soluble adhesives the greatest concern. l clay coatings molded fiber l varnish coatings containers l polymer barriers Recycling challenges l bioplastic barriers Molded fiber containers are commonly l non-tree fibers l laminated foils used as packaging for food products such l stamped foils as egg cartons, fast food containers, and l Definitions for non-fiber elements metalized foils more. The packaging material is resistant appear in the appendix. l wet strength resins to both heat and cold and non-fiber elements can be added to further increase l 33% or more of respondents rated these performance based on the need of the non-fiber elements as a challenge in mills. Being a challenge does not make some- packaging’s contents. thing not recyclable. 19 appendix definitions of “recyclable”

The following definition of “Recyclability” was U.S. Federal Trade Commission Green Guides approved by AF&PA members in 2019: Part 260 - Guides for the Use of Environmental Marketing Recyclability means the ability of a paper-based product to be Claims recycled into new paper, paperboard or other products. A paper- § 260.12 Recyclable Claims. based product is recyclable if it can be collected, separated or (a) It is deceptive to misrepresent, directly or by implication, otherwise recovered from the waste stream through recycling that a product or package is recyclable. A product or programs for use in manufacturing or assembling another item. package should not be marketed as recyclable unless it can be collected, separated, or otherwise recovered from the waste stream through an established recycling program for or use in manufacturing or assembling another item. Note: The complete text of this section, including examples, is available at: https://www.ftc.gov/sites/default/files/ attachments/press-releases/ftc-issues-revised-green- guides/greenguidesstatement.pdf (b) Marketers should clearly and prominently qualify recyclable claims to the extent necessary to avoid deception about the availability of recycling programs and collection sites to consumers. 20

(1) When recycling facilities are available to a substantial should emphasize the limited availability of recycling for majority of consumers or communities where the item is the product. sold, marketers can make unqualified recyclable claims. (c) Marketers can make unqualified recyclable claims for The term “substantial majority,” as used in this context, a product or package if the entire product or package, means at least 60 percent. excluding minor incidental components, is recyclable. For (2) When recycling facilities are available to less than a items that are partially made of recyclable components, substantial majority of consumers or communities marketers should clearly and prominently qualify the where the item is sold, marketers should qualify recyclable claim to avoid deception about which portions all recyclable claims. Marketers may always qualify are recyclable. recyclable claims by stating the percentage of consumers or communities that have access to facilities (d) If any component significantly limits the ability to recycle the that recycle the item. Alternatively, marketers may item, any recyclable claim would be deceptive. An item that use qualifications that vary in strength depending on is made from recyclable material, but, because of its shape, facility availability. The lower the level of access to an size, or some other attribute, is not accepted in recycling appropriate facility is, the more strongly the marketer programs, should not be marketed as recyclable. 21 appendix definitions of non-fiber elements

water-based inks of the is attained when water is lost from the glue line Water-based is an ink made with water rather than plastic by evaporation or absorption by the paper-based . or PVC. Water-based inks can be split into two main ingredients, Because the polymers are water soluble, bonds made using 8 water and pigment. 5 these adhesives have limited resistance to moisture and water. water soluble dyes hot melt adhesives A dye is a colored substance that chemically bonds to the paper- Hot melt adhesives are polymer based, and are thermoplastic based substrate to which it is being applied. The dye is applied in in nature, meaning they are solid at room temperature. The an aqueous solution. 6 two most popular types of hot melt adhesives are ethylene- vinyl acetate (EVA) and polyolefin, or metallocene. These are UV and EB inks generally applied as either a molten film or in a series of beads UV and EB curing typically describes the use of electron that is converted to a solid when the materials cool and set. (EB), ultraviolet (UV) or visible light to polymerize a combination Because hot melt adhesives do not utilize water or solvents, they of monomers and oligomers onto a paper-based substrate. also have a very fast set time, which makes them a popular kind The UV and EB material may be formulated into an ink, coating, of packaging adhesive. 9 adhesive or other product. 7 paper tape water soluble adhesives Gummed kraft paper tape is strong and durable. It has a water- Water soluble adhesives are supplied as pre-mixed solutions, or activated bond and is ideal for use with corrugated shipping are formulated as dry powders, which must then be mixed with boxes. Paper tape keeps goods totally secure while in transit and water in order to obtain its adhesive properties. The strength storage. 10 22 polymer tape holding wet or iced products such as fresh fruits and vegetables, tape is ideal for sealing light-weight packaged goods meat, poultry, and seafood. 15 that put little to no stress on a during shipping. 11 polymer barriers pressure sensitive labels Polyolefins provide functional and sustainable barrier effects against A pressure-sensitive , or self-adhesive label, is made up of two water, oil and grease migration on paper-based packaging. PE, or layers: a face stock and an adhesive. The face stock is the main part , is the most commonly used barrier coating. Typical of the label. The material could be paper, poly film or metallic foil. end uses are: drinking cups and packages for frozen food, ice cream For specific applications, a topcoat or laminate may be applied to and yogurt. HDPE-coated paperboard is used for moisture-sensitive protect the label artwork or enhance certain areas of the design. The dry foods. PET, or polyethylene terephthalate, provides a barrier adhesive is what makes the label stick to the surface of the paper- and performs other functions, such as heat resistance and act as based packaging. The adhesive type will depend on the application an excellent grease barrier. Typical end uses include: ovenable that the label will be used for. For a label that is only going to be used trays, reheatable product packages and bakery products. PP, or once, as on a paper-based shipping carton, a strong adhesive isn’t polypropylene, coating offers heat resistance for microwave oven and necessary. 12 is also suitable for deep freezing. Typical end uses are: cups and trays clay coatings for microwave oven and frozen food. 16 A thin layer of kaolin coated onto paperboard in order to improve its surface. Used on unbleached or natural Kraft paperboard. 13 bioplastic barriers Renewable biopolymers used as barrier coatings on paper-based varnish coatings packaging retard moisture transfer in food products, are good A clear ink which can be either gloss, satin or matte which can be oxygen and oil barriers, and are biodegradable. The choice of used for protection or to improve aesthetic appearance. 14 materials for a coating is largely dependent on its desired function. wax coatings Biopolymer‐based packaging materials originate from naturally Wax [curtain] coatings on boxes have traditionally been used as a renewable resources such as polysaccharides, proteins, and lipids or moisture barrier to preserve the strength of a corrugated combinations of those components. 17 23 metals barrier to moisture, gases and light, whereas paper provides stiffness, Metals are used as handles on packaging and as ends on composite strength and shape. 19 spiral paperboard cans. Metal staples are generally not considered a stamped foils challenge and are easily removed during the recycling process. Foil stamping is a decorative relief printing method in which foils are plastics transferred to a surface at high temperatures. Pressure and heat cause Plastics are used as ends on composite spiral paperboard cans and the relevant sections of the foil to become detached from the carrier as caps and spouts for liquid packaging. Plastic coatings are defined material and become bonded with the printing surface. separately (polymer barriers and bioplastic barriers) and are not metalized foils considered in this category. Metalized films are decorative polymer films coated with a thin layer of polymer windows metal, usually aluminum. They offer the glossy metallic appearance of Packaging with polymer windows combine the strength and stability of an aluminum foil at a reduced weight and cost. They are widely used corrugated, solid paperboard or boxes with a visibility for decorative purposes. panel that allows the consumer to see what they are buying. The wet strength resins materials most often used in windows are polyethylene terephthalate Wet strength resins are a necessary and critical papermaking additive (PET) and polyvinyl chloride (PVC) plastics. 18 for many grades of paperboard and specialty packaging. Operational variables like the amount and type of recycled fiber and , refining, laminated foils and other wet end additives, can impact the efficiency of wet strength Laminates are multi-layers of foil, paper and/or plastics that may be resins. 20 utilized selectively according to the specific need. In combination, the various laminates provide more strength and non-tree fibers barrier protection than the individual material (monofilm). Laminates “Tree-free” and “alternative fiber” products are generally made of hemp, of paper/foil/polyethylene composition rely on plastic layers for heat kenaf (a plant similar to cotton), bamboo, or agricultural residue from sealing (forming leak-tight containers). Aluminum foil provides a sugarcane or straw. 21 24 appendix insights from mills

An analysis of responses to the mill questionnaire insights from mills into recycling that rated one or more of the foil treatments as packaging with foil treatments easier to recycle showed the following: Recovered fiber use in manufacturing: Improvements in recycling technology and l The majority of mills in this group use predominantly the ability to use thinner foils have made foil recovered fiber for furnish (76-100 percent). Among treatments easier to recycle than they have been them: historically. • 55 percent rate “stamped foils” as easier to recycle A majority of mills reported that there is no • 60 percent rate “metalized foils” as easier to recycle • 56 percent rate “laminated foils” as easier to recycle meaningful difference between how the different l kinds of foil treatments are managed. A sizeable minority of mills (26-50 percent) use less recovered fiber for furnish. Among them: • 32 percent rate “stamped foils” as easier to recycle • 25 percent rate “metalized foils” as easier to recycle • 26 percent rate “laminated foils” as easier to recycle 25 insights from mills into recycling packaging with foil treatments (cont’d)

Products manufactured: Observations about the different kinds of foil l Nearly three-fourths of the mills treatments: manufacture . l Metal on poly is easier to deal with. It’s l A minority (14 percent) manufacture easier to get the poly off the board than Uncoated Recycled Boxboard. metal and very thin metal will stick to the poly. Pulping process: l Stamped foil is not as severe [because] l The great majority (approximately 80 stamping tends to involve less foil. percent) of these mills utilize Continuous- l Metalized coatings are more problematic Low Consistency pulping. than stamping. l Mills in this group utilized other pulping l Metalized films are very thin, and the plastic process to: 9 percent of mills reported backing is difficult to separate. utilizing Batch, Continuous-High Consistency and/or pulping. NOTE: Mills were able to select more than one response option for this question. 26

An analysis of responses to the mill questionnaire insights from mills into that rated wet strength resins as easier to recycle recycling packaging with showed the following: wet strength resins Recovered fiber use in manufacturing: l More than half of these mills use predominantly (76- Respondents are sure that wet strength resins 100 percent) recovered fiber as furnish. are acceptable in small amounts. How much is l More than one-third use less (26-50 percent) recovered “too much” varies, anywhere from “less than 2 fiber as furnish. percent” to “less than 5 percent” to “less than 10 Products manufactured: percent” of the bale. l Nearly two-thirds of the mills manufacture Wet strength resins create significant yield loss Containerboard. and higher waste, presenting a higher cost to l The next most frequent product made by this group of process while generating less output for mills. mills (14 percent) is Uncoated Recycled Boxboard. Pulping process: l Nearly all (86 percent) of the mills in this group utilize Continuous-Low Consistency Pulping. l More than one-fourth (29 percent) utilize Batch pulping. NOTE: Mills were able to select more than one response option for this question. 27 appendix recyclability standards & testing facilities

This Appendix provides an inventory of existing recyclability standard and testing facilities that are available for paper-based packaging. As designers and manufacturers of paper-based packaging consider how recyclable their current packaging is, and design new packages, there are resources in this guide that may be of assistance.

For each standard and testing facility, a brief overview and a link to the organization’s website is provided for further detail and contact information. 28

Fibre Box Association® – Corrugated Box and Recycling Corrugated ” published in 2013 Alternative Coating Standard contains a test method and test report. Part 1 determines the repulpability of treated corrugated 500 Park Boulevard, Suite 985, Itasca, IL 60143 by determining fiber-on-fiber yield when the treated Phone: 847-364-9600 E-mail: [email protected] corrugated container is processed in accordance with this URL: fibrebox.org standard. Certain coating treatments used on corrugated boxes Part 2 determines the recyclability of the treated to provide a practical and economical way of shipping corrugated container by evaluating its effect on mill perishable products such as meat, seafood, produce. The operations and finished products when it is added to same coatings can also make recycling the containers a untreated corrugated in the amounts specified. challenge, imposing financial and logistical burdens on Full details on the test method and test report can be found mills. The Fibre Box Association (FBA) and the American at: https://www.corrugated.org/wp-content/uploads/PDFs/ Forest & Paper Association (AF&PA) formed a joint Recycling/Vol_Std_Protocol_2013.pdf committee to find alternatives to improve the recyclability Box manufacturers can register treatments and coated of corrugated containers by providing an alternative to the board combinations with the Fibre Box Association on an historically used wax coatings. ongoing basis if they have a lab approved by the FBA (3rd The working group evaluated the repulpability and party or internal) certify that treatment has passed the recyclability of various moisture barrier treatments in test protocol. Three approved labs are discussed in the order to establish a minimum threshold for moisture next section: WMU, NC State, and WIST at University of barrier coatings. The “Voluntary Standard for Repulping Wisconsin. 29

Western Michigan University WMU has taken a leading role in the testing methods for the – Recycling Pilot Plants recyclability of foodservice containers. WMU partnered with Global Green (an industry working group that helps businesses 4651 Campus Drive, Kalamazoo, MI 49008 increase profits by transforming waste into assets) in 2009 to Phone: 269-276-3533 URL: wmupilotplant.com develop a recyclability and repulpability protocol for fiber-based hot cups. This testing determined that considerable volumes of The Recycling Pilot Plants at Western Michigan University usable fiber from cup stock was being landfilled and that cups (WMU) in Kalamazoo, MI provides an outlet for companies designed for repulpability could be integrated within the OCC or to test new paper types, fibers, chemistries and equipment Mixed Paper streams and recycled. on a smaller scale, without having to interrupt their own production lines. The Pilot Plants also does R&D on paper and WMU has offered certifications since the mid-2000s that reflect related products, and provides recyclability certifications. The voluntary and generally agreed upon standards in the industry. website at http://wmupilotplant.com/recycling provides further WMU was approved to provide certification for the Fibre Box information. Voluntary Standard in 2007. By 2009 it had developed a testing protocol and certification of recyclability for OCC (or recovered The Pilot Plants is a large scale facility that can recycle, repulp and de-ink a wide variety of -consumer waste corrugated). WMU has offered a certification for SBS-E materials items including mixed office , magazines, food service since 2013. To qualify for certification, a material typically needs packaging, and a variety of packaging including old corrugated to produce 80% yield when repulped. containers (OCC). To date, WMU has tested hundreds of pulp WMU has partnered with several industry associations to and paper products and developed approved certifications for a provide certifications that meet their specific requirements such number of types of packaging. as the Fibre Box Association and How2Recycle. 30

NC State University – Pulp and Paper Bench-Scale Testing Technical Services Program • Adirondack 1-gallon (3.8-liter) Low-Consistency Benchtop Pulper 411 Dan Allen Drive, Raleigh, NC 27695 • Adirondack 2-gallon (7.6-liter) High-Consistency Benchtop Phone: 919-515-5790 E-mail: [email protected] Pulper URL: cnr.ncsu.edu/fb/facilities-and-services/fiber-recycling- • 3-gallon (11.4-liter) Benchtop Low-Consistency Pulper technical-services/ • Voith Laboratory Flat Screen • Pulmac Master Screen Within the School of Forest Biomaterials, NC State conducts • Modular Centrifugal Cleaner System R&D and provides technical services to the pulp and paper • Shinhama Laboratory Kneader industry. Research areas include: fiber recycling, including identification and removal; repulpability and Pilot-Scale Testing recyclability of barrier-treated (e.g. waxed) and other difficult • Black Clawson 200-gallon (760-liter) Hydrapulper materials; and enzymatic and agglomeration de-inking. • 50-gallon (190-liter) Pilot Pulper • Ahlstrom M200 Centrisorter Centrifugal Pressure Screen The Pulp and Paper Technical Services group supports pulp • Gauld Periflow 140 Centrifugal Pressure Screen and paper and allied industries with high quality, cost- • Beloit Pressurized Module effective technical services on a project basis. The group • Voith Atmospheric Flotation Cell provides all types of testing from small-scale laboratory • Bauer Hydrasieve Slanting Screen testing to pilot-scale production of large quantities of pulp • Renneberg Pilot Screw Press or paper. • Filtration Engineers Pilot Rotary Drum Filter Washer The group offers an assortment of equipment, described • Sunds CD-300 Mechanical Pulping Pilot Plant below, that can be used to treat small samples at bench scale or large samples at pilot scale. 31

University of Wisconsin, Stevens Point, WIST offers an extensive line of testing: Wisconsin Institute for Sustainable • ABC Pulping Liquor Test Technology – Paper Testing Services • Absorption, Water Drop (T432) • Ash Testing 525 degC (T211) D274 SCI, 2001 Fourth Avenue, University of Wisconsin - • Ash Testing 900 degC (T413) Stevens Point, Stevens Point, WI 54481-3897 • Automated Solvent Extraction Contacts: Lindsey Hoffman, 715-346-3796 or Lindsey. [email protected]; Brian Bandow, 715-346-3733, Brian. • Basis Weight, Paper and Paperboard (T410) [email protected] • Brightness (T525, T571) URL: uwsp.edu/wist/Pages/laboratory-services/testing- • Brit , Fines (Pulp) (T261) services.aspx • Bulk/Density (T220) • Burst (T403) At the University of Wisconsin, Stevens Point, the Wisconsin • Caliper (T411) Institute for Sustainable Technology (WIST) in the College of • Carbohydrate analysis Natural Resources, provides routine testing and analysis for • Carbohydrate analysis and Klason the . • Carboxymethylcellulose substitution The paper testing unit operates out of dedicated laboratories • Cobb Size Test (T441) and offers physical testing services for pulping and bleaching, • Consistency (T240) recyclability and repulpability, performed according to TAPPI, • Dirt Count with Handsheets (T205 and T563) ASTM or ISO standard methods. • Fatty Acid Analysis - Short Chain • Fatty Acid Analysis - Long Chain (2-20 Carbons) 32

WIST testing (cont’d) • PFI Mill: 5 pt. curve including freeness, handsheets and standard testing (T248) • Fiber Length Distribution: MorFi • Pulmac Master Screen Analysis (T274) • Fiber Length Distribution - Morfi w/shives or • Repulpability - Modified UWSP Version (UM 212 + coarseness Formation) • Folding/Endurance (T511) • Repulpability - TAPPI UM Method Only (UM 212) • Formation Analysis (Optest Micro-Scanner) • Ring Crush (T818) • Freeness (T227) • Sheffield Smoothness (T538) • Gloss (T480) • Sommerville Flat Screen (T278) • Gurley Porosity (T460) • Starch Analysis (T419) • Handsheet Preparation and Physical Testing Package • Stiffness: Taber (T566) (T220) • Tear (T414) Tensile: stretch, TEA, modulus (T494) • Handsheet Preparation Only (T 205) • TSO Test • (T 236) • Valley Beater (T200) • Klason Lignin (TAPPI 60(10):143(1977) • Viscosity (T230) • Moisture Analysis - Halogen Balance • Water Retention Value (UM 256) • Odor analysis • Wax Extraction Test (T405, T574) • Opacity (T519) • Wax Pick Test (T459) • Parker Print Surf (T555) • Zero-Span Tensile (T231) 33

SGS Integrated Paper Services – Paper which include regulatory testing, recyclability and/or Testing Services repulpability, and flushability testing. IPS closely follows ISO, ASTM, INDA and TAPPI test method 3211 E Capitol Dr., Appleton, WI 54911 Phone: 920-749-3040 URL: ipstesting.com standards. The following are examples of sustainability and regulatory related testing services: Also located at UWSP, Integrated Paper Services (IPS), Inc. • Determination of recycled content or Mixed Tropical is an independent testing lab (independent of WIST) for Hardwoods in paper-based materials pulp and paper, packaging, nonwovens, personal care • Analytical testing of substrates, inks and adhesives for products, medical supplies and allied industries. IPS Testing known “bad actors” was founded in Appleton, WI in 1989 and is an offshoot of the Institute of Paper Chemistry. IPS combines physical and • Recyclability/repulpability testing analytical testing with interpretive data analysis to offer • Physical testing for material reduction or evaluation of testing services that help improve and ensure the quality green alternatives of paper-based products and packaging. More information In partnership, IPS and WIST are approved to provide can be found at: https://ipstesting.com/overview-about/ certification for the Corrugated Packaging Alliance/Fiber Focusing exclusively on paper and nonwoven products, IPS Box Voluntary Standard for Repulping and Recycling has recently added services addressing . 34 appendix additional resources from other industry associations

RadTech: Recyclability of UV and EB Printed Paper There is a general perception that paper and/or board products Foil & Specialty Effects Association (FSEA) printed with UV or EB-cured inks and coatings cannot be recycled as The Foil & Specialty Effects Association (FSEA) has released compared to conventionally cured systems. From the paper mills to a new study on the repulpability of paper/board decorated the waste brokers, the consensus is that or incineration are with transfer foils, produced in conjunction with the the only ways to deal with such waste. In an effort to respond to these Georgia Tech Renewable Institute. The perceptions, RadTech, the industry group for companies involved in association has been proactive in working to separate the UV and EB processing, commissioned the Beloit Corporation to do a decorated products that FSEA members provide (produced “blind” study of various printed and coated papers to help understand via hot foil, cold foil or digital foil transfer processes, as well ink and coating behavior relative to repulping and deinking. as transfer metallization of board or paper), from the use Ultimately the study found that UV- and EB-printed and coated of foil laminated paper or board, which includes the plastic paper can be recycled into tissue and/or grades using film and can be more difficult to recycle or repulp. The study commercially available equipment. Download the full study at: demonstrates that transfer foil decorated paper and board https://www.radtech.org/images/sustainability_pdfs/Recyclability.pdf do not create problems in the recyclability/repulpability of paper and/or board in a common repulping process. To receive a copy of the new study visit https://www. postpressmag.com/articles/2020/sustainability 35

Carton Council: Gable Top and Aseptic Carton Recycling Gable top and aseptic cartons can be recycled in many residential recycling programs. The Carton Council is Foodservice Packaging Institute (FPI): committed to building a sustainable infrastructure for carton recycling nationwide and works to add access to Recyclability of Paper Cups carton recycling throughout the U.S. For more information, Paper cups can be recycled, and a number of leading cities visit https://www.cartonopportunities.org are successfully recovering paper cups in residential recycling programs. FPI is working to increase recycling in the U.S. and offers resources for the paper-based packaging industry, as well as consumers. Visit https://www.recyclepapercups.org 36 appendix endnotes

1 AF&PA (2014) 2014 AF&PA Community Survey 12 Weber Packaging Solutions 2 TAPPI, How is Paper Recycled? (Paper U, Earth 13 gwp.co.uk Answers: 2001). https://tappi.org 14 gwp.co.uk 3 AF&PA (2020): Paper Industry Capacity & 15 corrugated.org Fiber Consumption Survey (2019-2020) 16 storaenso.com 4 National Council on Air and Stream 17 Khwaldia, K., Arab-Terany, E. & Desobry, Improvement. (2019). Fiber cycle longevity S. (2009). Biopolymer coatings on paper and fresh fiber requirements for the North packaging materials. Comprehensive American paper and board industry. Reviews in Food Science and Food Safety, 5 Superior Printing 9(1), p. 82-91. https://doi.org/10.1111/ j.1541-4337.2009.00095.x 6 Booth, G. (2000). Dyes, general survey. 18 Ullmann’s Encyclopedia of Industrial pakfactory.com Chemistry. https://onlinelibrary.wiley.com/ 19 Kirwan, M., Plant, S. & Strawbridge. J. doi/10.1002/14356007.a09_073 (2011). Plastics in food packaging. In R. 7 RadTech Coles & M. Kirwan (Eds.), Food packaging technology (2nd ed., pp. 157-212). Wiley- 8 hotmelt.com Blackwell. ISBN 978-1-4051-8910-1 9 hotmelt.com 20 https://www.ecolab.com/offerings/wet- 10 pluspackaging.com strength-additives 11 pluspackaging.com 21 boisepaper.com “Alternative Fibers”