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 recycling, 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 Adhesives ..................................................................................................................................... 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 Labels ...........................................................................................................................................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 packaging waste ............................................................................. 17 Material selection ........................................................................................................................ 26 Figure 4: Flexible plastic mechanical recycling process ............................................................... 19 Polymer choice ................................................................................................................................ 27 Figure 5: Preference for plastic recycling streams from post-consumer Paper and paper labels .................................................................................................................... 30 polyolefin-based flexible packaging ............................................................................................ 23 Aluminium foil ................................................................................................................................. 30 Figure 6: Elements of a flexible packaging structure ................................................................... 24 Barrier layers and coatings ............................................................................................................. 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