challenges for non bottle rigid container molders to comply with pcr legislation may 2000 l.
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Challenges for Non-Bottle Rigid Container Molders to Comply With PCR Legislation May 2000 PowerPoint Presentation
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Challenges for Non-Bottle Rigid Container Molders to Comply With PCR Legislation May 2000 - PowerPoint PPT Presentation


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Challenges for Non-Bottle Rigid Container Molders to Comply With PCR Legislation May 2000. Topics. Rigid plastic container overview Processing Market overview Recycling issues Plastic container resin and molding technology Lightweighting Industry trends California regulations.

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Presentation Transcript
slide2

Topics

  • Rigid plastic container overview
      • Processing
      • Market overview
  • Recycling issues
  • Plastic container resin and molding technology
      • Lightweighting
      • Industry trends
  • California regulations
slide3

Packaging plastic options

  • Blow molding
    • Bottle formed with small opening
  • Vacuum thermoforming
    • Sheet of plastic melted on a steel mold
  • Injection molding
    • Melt resin pellets
    • Forced into a steel mold
    • Cooled to form part
slide4

North America -- Total Plastics Consumption

Non-Bottle Rigid Containers Account for only 3% of the total plastics stream

slide5

Plastics Collection Programs

Source: RW Beck

1Actual is higher due to non-responding communities.

slide7

Recycling Issues

  • Variety of resins used in rigid packaging
  • Melt flow index within resin families

High Density Polyethylene

PackageMelt FlowFlows Like

Milk jugs 1 melt Honey

1 gallon industrial 20 melt Syrup

Butter tub 50 melt Salad dressing

Lids 100 melt Water

slide8

Non-Bottle Rigid Containers - Barriers to Recycling

  • Relatively small size of waste stream
  • Many polymer types - different polymer performance attributes (PP; HDPE; LLDPE; PS; PET; PVC)
    • only PP, HDPE and LLDPE recyclable as co-mingled - all polyolefins
  • Sorting technology not yet developed
  • Even within single polymer streams - many polymer types --- (eg. different melt flow resins)
slide9

Injection molders use highly-engineered resins to attain thinwalling (lightweighting)

  • High melt index resins > 40-100 melts
  • PCR 18 to 1 melt index
  • Must thicken part to use PCR
    • Increased energy cost
    • More plastic in landfill
    • Consumers will have increased costs
slide10

2000 container vs. 1985 container

  • 46% less plastic
  • 200 million containers used annually in U.S.
  • 32 million lbs. of resin
  • 15 million lbs of resin saved
  • 1,500 truckloads of plastic not going to the waste stream annually
slide11

Polypropylene Dairy ContainersCase Study Example

Wax Paper (1970’s)

Polypropylene (PP) (Mid-1980’s)

PP - 2nd generation technology 1990’s

33% Reduction

PP - 3rd generation technology 2000’s (specialized resins)

slide12

Technology Trends - Rigid Plastic Containers

  • Resin and polymer processing technology advancing
    • Lightweight
    • Increase strength of containers
  • Higher production rates and lower unit energy consumption
  • More customized and tailored resins --- to minimize resin consumption, increase production rates and reduce costs

Major Environmental Benefits

Resource Conservation - lighter weight packaging/less raw materials usage

Less Energy/Emissions in fabrication & shipping

slide13

Key Environmental Concerns

Heavier Gauge Containers

Recycle-Content Resin Trend

Resin Technology Trend

Increased Light-weighting

slide14

Compliance with current SB135

  • Lightweight containers
  • Limited PCR usage
slide15

California-Proposed Regulations/Issues

  • Recycle-Content Resins
  • Source Reduction
  • No FDA Food Grade resin supply available in higher technology resins
  • Traceability of PCR resins
  • Lower melt flow resins will tend to drive processors towards heavier containers
  • Cost reduction is already providing adequate incentives
  • Would penalize companies who source-reduced early -- lower base year container weight
slide17

Find and grow markets that can produce products using PCR

  • Use R&D departments of resin companies, mold makers and machine manufacturers to further develop engineered resins to allow lighter part weights
  • Today the plastic packaging industry gives the consumers their preferred packaging, a reusable, recyclable, resealable, lightweight container. The future can be even brighter with the use of technology tofurther reduce plastic waste.