Ahead of the Petcore Europe Thermoforms Conference in Dijon, France on 27-28 May, the technical manager of Petcore Europe's thermoforming working group, Jose-Antonio Alarcon, spoke to Argus about progress in the European tray-to-tray recycling market.
Since we attended the annual event last year in Granada, Spain what has changed for the market?
We don't see big changes. Collection is mostly the same, but there have been some developments on recycling projects. The appetite for recycling of tray-to-tray is growing.
We have seen more players coming to operate in the tray-to-tray market over the last year, and more capacity is expected to start during this year. Petcore are aiming to make an study of the state of play for the thermoform industry in Europe to have a clear view on the real market size and the final application usage. The distribution between the food contact and non-food contacts, and also between mono and multi-layer, are essential for us and will be discussed in France.
Following on from the success of last year's conference, what topics and discussions are you hoping will come up at this year's event?
We want to keep energising the market, and building on the momentum. We have five pillars in the thermoforming working group that will be represented at the conference supporting the initiatives in the market.
The first one is collection and sorting. If the material is not collected, it is not sorted, it is not recycled, period. We will be visiting a state-of-the-art sorting centre where they separate bottles and trays into mono- and multi-layer streams. The main challenge is how can these best practices be expanded to the rest of Europe.
The second is recycling technologies. This is important, because you cannot use the same technologies for recycling bottle and trays because the physical properties of trays are not the same as bottles. Trays are often thinner and more brittle, they generate more dust and need to be treated more gently.
Third is food contact, because we need to get the food contact trays back and into the closed loop. The majority of tray packaging placed on the market is in food contact applications, but there is not currently much progress on separate tray collection. There is work to be done in that direction.
Then we have design for recycling and standardisation. If you don't design properly for recycling, then it will be very difficult for the market to scale up.
And lastly is communication. Consumers need to know that trays can be recycled just like bottles, and we need people engaged.
We also have presentations from the European Commission and legislative specialists as this is an important factor in the outlook for the market.
Last year there was no specific legislation dedicated to thermoforms. Now we have the Packaging and Packaging Waste Regulation (PPWR) that passed into legislation and has mandated recycle content targets. So is this a positive?
There are some positives and negatives. Yes, in the PPWR there is mandated recycled content targets for contact sensitive and non-contact sensitive packaging that will directly impact the tray market. Of course, this should move more people toward the use of tray flake and towards separate collection for tray.
One of the impacts of legislation is that a lot of countries are moving to deposit return scheme (DRS) collection on bottles, which is deducting a lot of bottle from the regular yellow bin collection. So there will be a higher proportion of tray coming from this collection which could be a good opportunity for the circularity of trays if this waste is managed properly.
And the recycled content targets should give a demand boost to the tray-to-tray market. We also have recycled content targets into bottles from the Single Use Plastics Directive (SUPD) meaning more and more bottle flakes are going back to bottles so that's a good opportunity for tray flakes.
PPWR targets 30pc recycled content for contact sensitive packaging and 35pc for non-contact sensitive packaging by 2030. Will Europe be able to reach these targets in the tray market?
It could, and it is possible, but it is ambitious. At this time, we are a long way from that point on tray-to-tray and it is very complicated. If we look to the bottle market, these percentages are achievable. Around 70pc of bottles are collected on average in Europe, but less than 30pc of trays. If we achieve similar collection volumes for trays then around 30pc recycled content should be feasible. But it will be challenging.
At the moment bottle flake prices are at a significant premium to the virgin PET, which is impacting demand particularly in thermoforming applications and other cost saving markets like strapping and fibre. What impact could this have for PET tray flakes?
People try to minimise their impact on the balance sheet, bottom line so less competitive prices versus virgin for rPET bottle flakes and pellets could spur more interest in tray. And maybe with the additional demand for bottle flake or food grade pellets from legislation and recycled content targets, people are looking for an alternative source so that they're not having to compete with that bottle flake market. But for PETCORE the focus is not on cost, our intention is that every package place on the market is collected, sorted and recycled.
Over the last 12 months, we've seen quite a few chemical recycling projects being delayed or deferred. Is the difficult business environment across the whole industry an additional challenge for scaling up tray-to-tray?
Of course there are challenges. We need to look at how the bottle recycling market has changed in the past 15 years with collection, technology, volume, quality, capacity etc., and the tray market is much later in the in the evolution, so it will take some time in order to achieve a similar situation as the bottle market. Of course, we expect that the speed of acceleration to reach the point of maturity to be faster for trays because we can take some learnings from previous experiences.
Five years ago, trays were considered a contaminant at bottle sorting plants, and what we see today is that trays have the possibility to be a properly recycled stream providing another outlet of waste for sorters and recyclers.
We need the material to be collected and it will require investment of course. The current infrastructure may be sufficient if managed properly. To increase the number of streams collected and volumes there may not be the need to invest in new infrastructure but just to boost current infrastructures.
Chemical recycling is also part of the picture. There is a place for everyone, and mechanical and chemical are absolutely complementary. At the end of the day, we need to try to recover as much material as possible, then minimise the use of virgin resources so we know streams that can be as effective as possible.
