New developments in marker technologies for sorting plastic packaging should not be viewed as ‘the answer’ to increasing recycling rates.

While methods to detect different polymer types, such as fluorescent pigments and digital watermarks, offer exciting potential they should only be seen as a way to safeguard quality, asserts Richard McKinlay, Axion’s Head of Engineering & Research.

Meanwhile, existing Near Infrared (NIR) technology still has much ‘unexploited potential’ in recovering more packaging such as polypropylene (PP) from rigid plastics, polyethylene (PE) and PP films, which would go a long way to increasing recycling rates, he suggests.

Diversification in the plastics packaging market is leaving the established infrastructure behind. NIR technology detects polymer type, which for many years was sufficient to recover high quality PET, HDPE, LDPE film and PP, but this is changing.

Innovation in packaging has led to a more complex waste stream that contains many different components. For example, a shift for UHT milk from recyclable HDPE bottles into opaque PET containers has a negative effect on recycling. The growing use of PET in non-food products can lead to challenges when using recycled PET in new food packaging.

“This shift has brought forward the need for an alternative to NIR that can sort material on more criteria, to protect existing recycling processes and drive up quality to access higher value markets,” says Richard.

Several projects, bringing together companies throughout the supply chain, are currently researching marker techniques that provide detailed information on what packaging can and cannot be recycled. Two methods of marking being developed are fluorescent pigments and digital watermarks.

Invisible in normal lighting conditions, fluorescent pigments are easily detected under ultraviolet light. Specially chosen for optimum performance while minimising cost, they are safe for food contact applications.

Digital watermarks are patterns that can be applied in label or packaging design, or directly to the polymer surface. Having minimal visual impact, they can be detected by a camera and created at very low cost. Each marker can hold a large amount of data, such as material composition, original contents and suitability for recycling.

The development of fluorescent pigments is significantly further ahead than digital watermarking, with some European projects already completed and other close to completion.

“There is, therefore a better understanding of efficacy of fluorescent pigments. There are still many unknowns about watermarking and more independent studies are needed,” continues Richard. “Watermarking could be a powerful tool because of how much data it can hold and brand owners can gauge how much of their packaging is recycled.”

While markers offer a useful way to detect differences between food and non-food packaging, such as PET drinks bottles and PET detergent bottles, Richard warns that taking this route could lead to manufacturers using less recyclable packaging structures in future. For example, using more PET in non-food applications and reducing the subsequent quality of recyclable material.

He concludes: “People are approaching this marker technology as ‘the answer’ to increasing recycling targets. To me, it’s not. In my opinion, this marker technology should only be seen as a way to safeguard quality of materials for recycling. In terms of increasing recycling rates, I think it will have absolutely no impact. The only way to increase recycling rates is to do more sorting on more of the plastic fractions that are currently going to energy recovery because it’s not economically viable to recover them.”

Recycled polymers have significantly lower carbon footprint than oil-based virgin plastics – up to 89% for ABS – according to latest research by Axion Polymers.

Axion’s 2017 Axpoly® Carbon Footprint Analysis also reveals a carbon saving of 82.5% for recycled (HIPS) and 73% for recycled (PP).

The CO2 savings are large. The team calculated that using just one tonne of Axpoly ABS instead of virgin material to make goods would give a saving of 3,380 kgs of CO2 – equivalent to a 40ft articulated lorry transporting the material 2,272 miles. On a full 20 tonnes load, the same lorry could be driven 45,445 miles or almost twice round the world on the equivalent CO2 savings.

Axion Polymers produces three types of recycled polymer: Axpoly® PP (polypropylene), ABS (Acrylonitrile Butadiene Styrene) and HIPS (high impact polystyrene),  the most common plastics used in the automotive and E&E markets over the past 15 years.

The Axpoly® polymers can be used as a direct replacement for virgin polymer, or combined with virgin polymers to produce a high-grade polymer with recycled content that can be used in demanding applications.

The new study was prompted by recent investment in more efficient separation processes and improving throughput that has increased the yield of finished polymers. The methodology was based on similar process stages to making oil-based polymer from crude oil to allow a direct comparison between the process routes and resulting carbon emissions.

The calculations were done by Axion’s Head of Engineering & Research, Richard McKinlay who says: “These ‘new metrics’ of the circular economy are the numbers that need to be considered by designers and specifiers of polymer materials when selecting plastic for use in new parts and components on all types of consumer goods and vehicles.”

Axion Director Keith Freegard explains: “What we’ve confirmed is that as our process technology has developed, our throughput has increased, our efficiency has improved and our power consumption per unit output has got much better with lower wastage and better yield; then that all pays off in an improved carbon footprint per tonne of output product.”

He continues: “This proves to me that actually using a carbon footprint metric is a really good way of tracking if your process is an efficient conversion of waste into finished product.”

Keith says customers can benefit from their analysis by demonstrating the carbon savings credited to their finished moulded products. “We’ve already heard from some customers who are excited about having a new updated number on the savings that accrue to them. We’re also happy to provide a bespoke carbon analysis on their operations so they gain the benefit from the work we’ve done of measuring our own carbon footprint.”

RecoMed, the PVC medical devices take-back scheme, is a joint winner of the Waste Prevention category of the 2017 National Recycling Awards for its innovative approach to sustainable healthcare recycling.

It’s yet another accolade – the third in two years – for the unique UK-wide scheme, which is run by project partners Axion Consulting, a resource recovery specialist, and the British Plastics Federation (BPF). Set up in 2014, RecoMed supplies recycling containers, communication materials and collections to participating NHS and private hospitals.

Funded by VinylPlus, the voluntary commitment to sustainable development by the European PVC industry, the scheme provides an alternative, sustainable disposal route for waste medical items made from high-quality medical grade PVC. This material has been recycled back into new goods, such as horticultural products, by specialist recyclers.

Collecting the award at a ceremony at the London Hilton, Park Lane on behalf of Axion and the BPF, Axion’s Principal Consultant Jane Gardner said: “We’re thrilled and very proud to win this high profile award, which recognises the tremendous achievements of all participants and hospitals in recycling plastics from the medical waste stream.

“Now operating in ten hospitals, RecoMed continues to grow and is attracting more and more interest. The scope for development is huge as the scheme could ultimately be replicated across Europe. We are particularly impressed with the enthusiasm and commitment of clinicians without whom this scheme would not be possible,” she added.

Francisco Morcillo, Head of Public and Industrial Affairs at the BPF said: “RecoMed shows once again how PVC has come a long way when it comes to sustainability, becoming a guiding light for other materials. Not only PVC is a very cost-effective material with a great performance, it is also helping hospitals reducing their waste management costs whilst contributing to the principles of a circular economy.”

Praising the scheme, the judges commented: “This showed great initiative in changing behaviour in a sector that is notoriously difficult to establish effective waste segregation at source.”

The National Recycling Awards, organised by Materials Recycling World magazine, celebrate excellence, innovation and best practice across every aspect of waste management: recycling, recovery and reuse.

In 2016, RecoMed won the Sustainability category of the 2016 INOVYN Awards for its innovative approach to sustainable healthcare recycling. The previous year, RecoMed’s excellence in sustainability was recognised with the 2015 Association for Anaesthetic and Respiratory Device Suppliers (Barema) and the Association of Anaesthetists of Great Britain and Ireland (AAGBI) Environment Award.

It is estimated that up to 2,250 tonnes of PVC could be recycled by collecting items, such as anaesthetic facemasks, oxygen masks and associated tubing, from UK hospitals. Participating hospitals save money on waste disposal costs by recycling non-infectious PVC medical items instead of sending them to clinical waste steams which are either incinerated or sent to specialist landfill sites.

Axion staff took part in the annual Great Manchester Run and raised well over £3,000 for charity in memory of our late colleague Simon Wilkinson who passed away from cancer last summer.

Axion’s fund-raising team effort completely smashed an original target of more than £1,500 in aid of The Christie Hospital where Simon received treatment.

Twenty five employees from across Axion’s three sites competed in the 10k event – the largest of its type in Europe – at the end of May.

Sam Haig, Axion’s Head of Engineering & Research, who worked with Simon, a Principal Engineer, commented: “All of the team members from Axion felt very privileged to take part in the Great Manchester Run on Sunday 28th. The tragic events of the previous Monday made it a very emotional day, but there was a hugely positive attitude throughout the city and along the course, with thousands turning out to support the runners.”

Sam continued: “Simon was a very popular, professional and respected colleague. Axion is proud to have been able to help raise £3,416 for The Christie, in his memory. Special mention must go to Simon’s children David and Amy, who took part in the race alongside the Axion team, and his son Jack, who sped round the Junior race to finish in second place.”

He added: “The weather held up nicely, and the sun came out just in time for the team to enjoy a refreshing drink together afterwards!”

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