Consistent Collections of Flexible Plastics
In 2021, 44 local authorities in the UK collected plastic films, out of a total of 410. Even then, ten of these only collected plastic carrier bags, which resulted in 25,000 tonnes of plastic film being collected for recycling out of the 341,000 tonnes put on the market. That represents 4% of plastic collected at kerbside.[1]
This lack of consistency creates confusion for consumers, who do not necessarily know exactly which items of plastic packaging they can put out for recycling. It creates unnecessary complexity and makes simple messaging about what can or cannot be recycled in household collections difficult. If all plastic packaging were to be collected for recycling this would enable a clear message.
Most European countries provide for the collection of flexible packaging used by consumers (this is sometimes called ‘soft’ plastic packaging). The UK is one of the few that does not offer a comprehensive service. The collection in Europe is facilitated by funding provided by industry through Extended Producer Responsibility (EPR) schemes in operation within each country.[2]
To some degree, the lack of kerbside collection of flexible films has been mitigated by the major supermarkets stepping in to provide front-of-store collection points. Now most major supermarket chains operate some form of collection point for flexible packaging.
Two pieces of legislation will change the landscape for collecting flexible packaging for recycling. Consistent collection (now referred to by the UK government as ‘simpler recycling’) will mandate which types of packaging and materials will be collected and all local authorities will have to collect flexible materials. Extended Producer Responsibility (EPR) is designed to raise the funds required to pay for collecting and sorting the material.
One complexity is the infrastructure needed to recycle these materials. Currently, the capacity available in the UK cannot cope with the likely increase and currently the majority of flexible packaging is exported to recyclers in Europe.[3] The Packaging Recovery Note (PRN) system is an already existing system intended to generate the funds needed to invest in infrastructure to recycle flexible plastic packaging but currently we are not seeing evidence of the investment needed for the UK to recycle this particular waste stream in the quantities required to significantly reduce the country’s current reliance on exporting plastic waste for recycling.
What about the complex structures of flexible packaging materials?
Many flexible plastic materials are constructed from single materials such as low-density polyethylene (LDPE) and polypropylene (PP) and these mono material packs are relatively easy to recycle. Other packaging items can be made of multiple layers of different plastics or even incorporate layers of paper or aluminium. These complex structures can be valuable in terms of incorporating desirable properties into a flexible plastic packaging product that are not currently possible in mono material structures, such as long-life barriers to gases or water vapour.
These multi-layer materials can be difficult to separate from the mono material streams and are more complex to recycle. However, there is a lot of work being done in this area and advanced sorting systems such as Near Infrared (NIR) systems can sort materials more efficiently.
There is also a lot of research and development going on across the world to move from these complex structures to mono-material packs and considerable progress has been made in many areas. For example, some newer cheese packaging has removed the nylon inner barrier layer without significantly increasing the gauge (thickness) of the material while resulting in only a small reduction in shelf life.
Are there end markets for recycled flexible plastic packaging?
Present end markets for recycled flexible films include non-food contact packaging for polyolefins and various other non-packaging applications. This is due to regulatory barriers that prevent mechanically recycled film from being included in food contact packaging. Recent changes to laws in Europe allow new mechanical recycling technologies to be evaluated for use in direct food contact applications but there are currently no plans to implement these in the UK.
For polypropylene (PP) recycling, trials on various PP films, including those that are metallised (e.g. those used in crisp packaging), have been conducted. End markets presently exist for recycled PP within the automotive, horticulture, DIY and building industries.
End markets also exist for mixed polyolefin polymers, such as in pallets and street furniture.
At present, ‘chemical recycling’ is an umbrella term for a range of non-mechanical recycling processes, which are currently being developed to work at scale. However, many companies are now operating pilot plants across Europe and two commercial plants have been operating in Spain for several years. Over the next two to three years, the BPF expects up to seven companies to be operating in the UK (or have plans underway to reach operational capacity). Some of these companies are planning to run multiple sites. However, mechanical recycling will have to remain the main option until these non-mechanical (‘chemical’) recycling plants are operational.
Non-food-contact applications and non-packaging end markets will continue to be the main markets for recycled flexible packaging until chemical recycling is widely available or existing legislation is changed.
In conclusion…
End markets exist, methods of collection and separation exist, and a lot of developments are underway that will ensure circularity can be a reality for all flexible plastic packaging and films in the near future.
The introduction of the UK plastics tax is intended to generate a huge increase in demand for recycled plastic in plastic packaging. To meet this demand, the collection of feedstock (used flexible plastic packaging) needs to commence as soon as possible to provide recyclers with adequate material. In addition, early signalling from government of the intention to collect films is required, and it needs to be accounted for in the Consistent Collection (‘simpler recycling’) and EPR legislation currently passing through parliament. This will give investors in the UK the certainty they need to continue to invest in the separation facilities, wash plants, and recycling solutions, including advancing non-mechanical recycling technologies.
Collecting flexible packaging and films will result in lowering the environmental impact of these necessary products, reducing carbon-related emissions, enabling recycling targets to be met and resulting in a circular economy for more plastic packaging. Without collecting flexible plastic packaging for recycling in the near future, recycling targets are unlikely to be met, including those set in the UK Plastics Pact.
Importantly, collecting all plastic packaging (including flexible ‘soft’ plastic packaging) will also make the recycling of plastic much simpler and convenient for the consumer.
Sources and further information
1) RECOUP – UK Household Packaging Collection Survey 2023
2) Plastics Recyclers Europe - Flexible Films Market in Europe: State of Play (2020)
3) Wrap - Plastics Market Situation Report (2021)
Originally published June 2019
Last reviewed and updated July 2024
