European Packaging Trends, Recycled Bollards and Master Batches were on the agenda when the Australian Institute of Packaging (AIP) recently met with the Society of Plastics Engineers.
According to Peter Patterson, General Manager of Repeat Products Pty Ltd [RPA] trading as Replas Victoria, 'waste' is a word that may need redefinition in dictionaries.
"Waste is now a commercial tradable product, certainly in post consumer plastics," he says.
"Waste that used to go to landfill by paid collectors is now valued at as much as $1000 a tonne."
Patterson told a recent AIP meeting that RPA is now producing over 200 robust, high quality products from 100% recycled material diverted from Australia’s domestic and commercial waste streams.
The technology used by Replas allows waste to be converted into quality recycled products that compete economically with the virgin products they replace.
Australians annually produce 71kg of plastic waste per capita and that 90% of rubbish on beaches is plastic," he says.
"The waste was created by us and we have a responsibility to clean it up.”
" Replas gives plastic a better life the second time around," he says.
"Not only are Municipal Refuse Facilities and industry sources of plastic to recycle but a venture with Ritchies IGA supermarkets is in place where Replas collects plastic shopping bags returned by environmentally conscious consumers."
This reclaimed material uses less energy than melting virgin material and produces no pollution.
One PVC bottle in ten thousand will contaminate a PET recycle batch but at Replas non plastics such as paper labels are absorbed into the finished material without affecting the tensile strength of the product.
Waste is turned into all manner of outdoor furniture and building materials.
"We have become accustomed to hearing about the 3 Ps but Replas promote 8 Rs in consideration of plastic life cycles," Patterson explains.
"These are: - rethink- refuse-reduce-reuse-repair-recycle-recovery and release."
Reuse is not possible without original production and that was the subject addressed by Steve Coulton, Sales Manager, Acquos Masterbatch.
Coulton says problems associated with distortion and warpage in rigid plastic packaging can be overcome by way of improved part and tool design or through the addition of nucleation additives into the polymer.
"Acquos have recently developed a breakthrough in Masterbatch concentrate technology that reduces distortion in rigid plastic packaging resulting in faster processing and filling times," he says.
"The results include fewer rejects and processing headaches through controlled nucleation and re-crystallisation of the polymer during the cooling cycle."
A definition of Masterbatch is "a concentrated mixture of pigments and/or additives encapsulated during a heat process into a carrier resin which is then cooled and cut into a granular shape."
Masterbatch allows the processor to colour or modify raw polymer economically during the plastics manufacturing process.
Coulton says correct technical advice and selection of materials and processes can increase productivity by as much as 25% which is a good reason to take professional advice such as that provided by Acquos Masterbatch.
As would be expected the company now has a range of eco friendly colorants for use in biodegradable resin batching.
Dr Jefferson Hopewell, from Eco Products Agency, a third spearker at the event covered recent developments and trends in plastic packaging in Europe, with particular emphasis on changes and innovations in packaging practice in response to ecological considerations and legislation.
Hopewell argues that bioplastic is impossible to clearly define, given that PE made from both ethanol derived from sugar and materials originating from fossil fuel have an ethylene base .
"The test is of course if the material is capable of being broken down by decomposer organisms," Hopewell says.
According to Hopewell, EU countries have targets set under EU directive 94/62 EC dealing with waste minimisation and recycling that are backed by legislation, whereas Australia is pursuing industry self-regulation to achieve government targets.
Retailers and manufacturers in Europe have accepted the legislation and committed to the process of change.
One major department store has stated that by 2012 all packaging will be recyclable or compostable and that a 25% reduction in glass packaging will be achieved in the same time frame.
A confectionery manufacturer has committed to a 10% reduction in packaging materials overall with a whopping 25% in product sold for gifting.
This is an example of over packaging brought about by marketers tapping into the consumers desire to please!
Light weighting of PET bottles in England is an interesting study as records show extreme variances between the best of class and the worst.
If one gram of material can be removed from a PET bottle, 100 million units will deliver a saving of 100 tonne of material and 36 tonne of CO2e.
HDPE bottles in the UK can now be made in a closed loop with 30% of the feedstock being reclaimed material.
There are some examples of PET bottles made of 100% recycled material.
Bioplastic bottles currently have no recyclability as there is as yet no recycle infrastructure for PLA material but as the use grows something will eventuate.
Totally biodegradable food trays including the plastic wrapping was shown and explained as coming from consumer pressure, green competition and legislation.
Green competition is a new phenomenon as brand owners strive for market share and claim “mine is greener than yours.”
The AIP in Victoria is supported by Australian Industry Group and Michael Magelakis spoke about the involvement and the joint venture eduction courses being run in Melbourne.
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