By Dr. Andrew Dent, EVP of Research Material ConneXion
We are being faced with a monumental plastic problem. How are we going to approach true circularity in packaging – and specifically beauty packaging?
There has been a recent and essential approach to reducing virgin petroleum-based plastic in packaging through various methods that include the use of bio-based or renewable sources, upping the amount of recycled content, ‘dematerializing’ the packaging through thoughtful design and weight reduction via material replacement. These approaches are being championed by organizations such as The Ellen MacArthur Foundation and the Sustainable Packaging Coalition with many major brands making bold and admirable statements to reduce their virgin plastic footprint in the coming years.
I would like to add some additional insight to this challenge by making four recommendations about how to achieve some of these goals and, equally, to be realistic about our plastic use.
Each year, we are increasing the amount of plastics we produce globally by a staggering 10-15 millions tons, only 2.2 million tons of which was bioplastic production in 2022. A whopping 51% of plastic produced is for the purpose of single-use packaging and, while our total recycled plastic use has increased significantly, recycled content still only accounts for 6% of total plastic used. We are seeing great strides in bioplastic evolution, especially in the area of replacements of existing commodity polymers such as polyethylene, polypropylene and nylon, but this needs to increase exponentially to make any real impact.
Thus in addition to the existing initiatives to reduce virgin plastics we need to also simplify, chemically recycle, industrialize our bio-sources and I’ll probably get censured for this, prioritize these material innovations over concerns about carbon footprint.
Simplify your Chemistry.
This can happen in two ways. First of all, if you can keep your packaging to a few, commodity plastics, it will reduce the likelihood of using chemicals of concern. PP (polypropylene), PE (polyethylene), PET (polyethylene terephthalate) are the go-to’s not only because they are simpler, cleaner plastics, but they also have a greater chance of being recycled into valuable products for a second life. Also, if you can develop or use monomaterial packaging, using only one polymer type or polymer family, it means that you can again maximize your opportunities for recycling as evidenced by the recent launch of ‘Recycle Me’ toothpaste tubes from Colgate Palmolive using three different layers of polymer, all based around the polyolefin chemistry.
(polyolefins are the class of ethylene-based plastics that include EVA, EVOH, PP, and all the PE’s)
Monomaterial Packaging
Industrialized Bio-Sources
If we are to scale bio-based plastics and other material formats, we have to concentrate on sources that are already industrialized or those that can be ramped up to large volumes quickly and economically. Wood, cotton, castor oil, and chitosan (shrimp shells) are all viable sources that do not take from the existing food supply and can be rapidly redeployed for low-cost raw materials. Polymers that come from food plants or flora that are not produced in large volumes are not ideal. Focusing on sources that do not require land for production (such as algae, bacteria and fungi) could create needed production demand in non-arable land areas.
Rubbers, plastics and chemicals from Lignin
Advanced (Chemical) Recycling
Given the large increases in plastic use, we must get better at recycling. Simplifying chemistry can help, but recent developments in advanced recycling is where we could see real change happening on a major scale. This type of recycling uses chemistry to ‘dissolve’ the polymers rather than mechanically chopping them up. This method has many advantages such as the removal of color and additives from the plastic, without mechanical loss in performance – both of which can then create polymers with the same performance as virgin materials. Also, Chemical recycling is also much more forgiving with the types of plastics put into the mix, enabling a wider range of plastics to be recycled in the same system. To drive the change we need to see, we suggest looking into using plastics in your packaging that have come from this process.
This new pack has been created using SABIC’s certified recycled plastic, made through a ground-breaking recycling technology that can recycle mixed plastic waste otherwise destined for incineration or landfill.
Materials > Carbon Footprint
Lastly, if we are going to make real progress with these innovations, it will initially come at a cost in the form of increased CO2 emissions. Virgin plastic production is incredibly efficient – and to enable the successful implementation of new technologies, they must be allowed to evolve and improve. This will not be possible if they are held to the same CO2 output standards as materials that have been refined over decades.
Looking holistically at the plastic problem in packaging, the volume of plastic impacting our waterways and oceans is enormous – whereas the amount of CO2 generated from packaging plastics is insignificant when reviewed in context of the total amount of CO2 released into our atmosphere. While not ideal: let’s solve the waste issue first.
About Material ConneXion
Material ConneXion is the world’s leading material insights company, driving material innovation with a unique cross-industry approach.
For more than 25 years, Material ConneXion has been providing material solutions to the world’s most innovative brands. By meeting design challenges with creativity and a unique cross-industry perspective, Material ConneXion ensures that tomorrow’s products and spaces
start with thoughtful material selection.
About Dr. Andrew Dent
Dr. Andrew Dent is EVP of Materials Research at Material ConneXion and Chief Material Scientist at Material Bank, is known for his integrated approach to problem solving.
One of the world’s leading authorities on materials in design, Andrew has helped clients from start-ups and Fortune 500 companies take their products and spaces to the next level through innovative material selection and a unique cross-industry perspective.
Categorized in: Trends/Insights