LIFE CYCLE IMPACTS OF PLASTIC PACKAGING COMPARED TO SUBSTITUTES IN THE UNITED STATES AND CANADA Theoretical Substitution Analysis PREPARED FOR The Plastics Division of the American Chemistry Council (ACC) BY Franklin Associates, A Division of Eastern Research Group (ERG) April 2018 Table of Contents EXECUTIVE SUMMARY .................................................................................................................... 1 ES.1. INTRODUCTION & BACKGROUND....................................................................................... 1 ES.2. METHODOLOGY ..................................................................................................................... 3 ES.2.1. Functional Unit ................................................................................................................... 3 ES.2.2. Product Systems Studied ..................................................................................................... 4 ES.2.3. Data Sources ....................................................................................................................... 8 ES.2.4. Reuse & Recycling Modeling Approach .............................................................................. 8 ES.2.5. Key Assumptions ................................................................................................................ 9 ES.3. KEY FINDINGS ...................................................................................................................... 10 CHAPTER 1. GOAL & SCOPE DEFINITION .................................................................................. 17 1.1. GOAL ......................................................................................................................................... 17 1.2. SCOPE OF THE STUDY ............................................................................................................ 18 1.2.1. Functional Unit .................................................................................................................... 18 1.2.2. Product Systems Studied ...................................................................................................... 19 1.2.3. System Boundary ................................................................................................................. 23 1.2.4. Allocation Procedures .......................................................................................................... 27 1.2.5. Recycling Methodology ....................................................................................................... 27 1.2.6. Data Requirements ............................................................................................................... 30 1.2.7. Data Sources ........................................................................................................................ 32 1.2.8. Impact Assessment............................................................................................................... 37 1.2.9. Assumptions and Limitations ............................................................................................... 41 1.2.10. Critical Review of the Substitution Model Methodology ..................................................... 46 CHAPTER 2. SUBSTITUTION MODEL............................................................................................ 47 2.1. INTRODUCTION ....................................................................................................................... 47 2.1.1. Similarities .......................................................................................................................... 47 2.1.2. Differences .......................................................................................................................... 48 2.2. SUBSTITUTION MODEL OVERVIEW..................................................................................... 49 2.3. OTHER RIGID PACKAGING MARKETS ................................................................................. 55 2.3.1. Introduction ......................................................................................................................... 55 2.3.2. Non-Bulk Rigid Packaging ................................................................................................... 55 2.3.3. Rigid Protective Packaging .................................................................................................. 58 2.3.4. Rigid Bulk Packaging .......................................................................................................... 60 2.4. OTHER FLEXIBLE PACKAGING MARKETS.......................................................................... 66 2.4.1. Introduction ......................................................................................................................... 66 2.4.2. Converted Flexible Packaging .............................................................................................. 66 2.4.3. Flexible Protective Packaging .............................................................................................. 69 2.4.4. Flexible Bulk Packaging ...................................................................................................... 71 2.5. BEVERAGE PACKAGING MARKETS ..................................................................................... 78 2.6. CARRIER BAGS PACKAGING MARKETS.............................................................................. 84 2.7. CAPS AND CLOSURES MARKETS ......................................................................................... 88 2.7.1. Simultaneous Substitution Analysis ...................................................................................... 91 2.8. SHRINK AND STRETCH FILM PACKAGING MARKETS ...................................................... 95 CHAPTER 3. LIFE CYCLE INVENTORY ...................................................................................... 100 3.1. OVERVIEW ............................................................................................................................. 100 3.1.1. Methodology for Data Compilation/Verification ................................................................. 100 3.2. COMPARISON OF PACKAGING SYSTEM DISTRIBUTION SPECIFICATIONS ................. 100 3.3. PLASTIC PACKAGING SYSTEMS ......................................................................................... 101 3.3.1. Production of Plastic Resins ............................................................................................... 101 3.3.2. Plastic Converting Processes .............................................................................................. 101 CLIENTS\ACC\KC182695 ii 04.18.18 4103.00.001 3.4. NON-PLASTIC PACKAGING SYSTEMS ............................................................................... 103 3.4.1. Steel Packaging .................................................................................................................. 103 3.4.2. Aluminum Packaging ......................................................................................................... 105 3.4.3. Glass Packaging ................................................................................................................. 107 3.4.4. Paper, Paperboard, & Corrugated Packaging....................................................................... 108 3.4.5. Cork, Rubber, Textile, Wood, and Cellophane Packaging ................................................... 111 3.5. RECYCLING & END-OF-LIFE WASTE MANAGEMENT ..................................................... 112 3.5.1. Plastic Recycling ............................................................................................................... 112 3.5.2. Alternative Packaging Recycling ........................................................................................ 115 3.5.3. Disposal ............................................................................................................................. 126 CHAPTER 4. RESULTS FOR PACKAGING SYSTEMS ................................................................ 128 4.1. INTRODUCTION ..................................................................................................................... 128 4.2. COMPARATIVE WEIGHTS .................................................................................................... 128 4.3. OVERVIEW OF RESULTS ...................................................................................................... 130 4.4. ENERGY RESULTS................................................................................................................. 134 4.4.1. Cumulative Energy Demand............................................................................................... 134 4.4.2. Expended Energy ............................................................................................................... 136 4.5. WATER CONSUMPTION RESULTS ...................................................................................... 140 4.6. SOLID WASTE RESULTS ....................................................................................................... 142 4.6.1. Weight of Solid Waste ....................................................................................................... 142 4.6.2. Volume of Solid Waste ...................................................................................................... 145 4.7. GWP RESULTS.......................................................................................................................