CIRCULAR PLASTICS

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Circular Plastics : Making positive inroads

Podcast: Circular Plastics with H.B. Fuller’s Elizabeth Staab

New ALPLA plant brings design, development, and production to Thai customers

Playbook lays out guidelines for mechanical recycling of mixed plastic waste

Polystyrene mechanically recycled into yoghurt cups in supermarket ‘first’

Circular Plastics :
Making positive inroads

We’re all familiar with the shocking statistics by now: in 1950, the world produced just two million tonnes of plastics. It now produces over 450 million tonnes.

However, according to a Plastics Europe report: circular plastics now account for 13.5% in new plastic products manufactured in Europe. This means that the European plastics system is halfway towards the interim ambition – established in the ‘Plastics Transition’ roadmap – to use 25% of plastics from circular sources in new products by 2030.

Positive inroads into our shared waste problem.

To take a closer look into our ‘topic of the month’ Libby Munford, Editor, Packaging Europe, is pleased to share expert opinion from Elizabeth Staab, Global Packaging Sustainability Manager at H.B. Fuller.

Strategic Challenges

We kick off by exploring the strategic challenges facing the circular economy when it comes to plastics.

She comments, “For rigid and flexible plastics, I’d say the most challenging aspect really for the circular economy is that there are so many players that must cooperate”. She stresses that infrastructure is “absolutely crucial” for plastics.

As an adhesive developer and manufacturer, H.B. Fuller focuses on continuous development – they “cannot wait for guidelines” (Here, referencing the ‘Designed for Recyclability’ guidelines that are ready to come into force, in 2027, as part of the PPWR) – underlining that they have been working on adhesives, for example, “that are designed for recyclability for many years now -whether for labels on beverage containers, for flexible packaging, intended for mechanical recycling.”

H.B. Fuller, therefore, already has several innovations in its product line. Staab stresses, “Because substrates keep developing with increased recycled content, we are already well into many years’ worth of development and new product launches, and that will continue for the foreseeable future.”

It seems, that companies, such as H.B. Fuller, within the packaging industry, keep steps ahead of legislation – pushing innovation forwards in order to stay ahead and on top of imminent guidelines.

“Because substrates keep developing with increased recycled content, we are already well into many years’ worth of development and new product launches, and that will continue for the foreseeable future.”

From pillar to post

Talking in broader terms, Elizabeth Staab confirms they continue to use known existing raw materials, but of course, are always looking for alternative raw materials and sustainable alternatives (Such as renewable raw materials or chemically recycled raw materials).

Our conversation leads on to the next question: What challenges do you face when it comes to meeting the various recyclability standards across Europe? How do you ensure alignment?

“We really do see differences from one country to the next,” states Elizabeth Staab. Specifically focusing on PET labelling, Staab notes considerable differences in the collection and sorting rates, outlining that it makes a huge difference if a country has a Deposit Return Scheme. She shares that the PPWR demands that by 2028, all EU countries have Deposit Return schemes – “This will considerably help and boost the overall recycling rate of PET”.

It’s apparent that steps are being taken towards a more joined up approach, a long overdue response to a widespread issue, which should see a huge increase in recycling rates.

Mirroring Reality

There has long been discussion and grey areas around the recyclability of products compared with how/whether they are being recycled in reality, due to a wide range of factors.

Staab states that H. B. Fuller’s products must live up to the range of certifications and standards across the European Union. However, she divulges, “Of course, we are relying on the fact that these testing protocols, in a laboratory, are mirroring as best as possible what is happening in reality at the recyclers. There are many studies and discussions ongoing about how well that represents what is actually happening in the real world.”

With incoming legislation and the support of the PPWR, we expect to see more clarity and unification across the industry when it comes to this particular issue.

“This will considerably help and boost the overall recycling rate of PET”

Elizabeth Staab
Global Packaging Sustainability Manager at H.B. Fuller

Working in Unison

My final question for Elizabeth Staab is: how do we work together across the value chain over the next few years to meet requirements, and ensure optimum design and infrastructure as well?

She responds, “I’d say overall the industry is really trying hard to work together already, if we look at the various industry associations that are working along the supply chain for a specific material type, whether that’s fibre-based or plastics, of course…”

“And these associations, they really span the entire supply chain, starting with raw material suppliers, recyclers, brands, and everybody in between. So that communication is already ongoing. Obviously, each company has their own interests at heart, but at the end, we need to achieve the circular economy and also make sure that the packaging industry is functioning well under the PPWR, so more work needs to be done.”

Communication is key, as always, and an understanding that certain compromises need to be made along the way. “I think overall, we need more investment in state-of-the-art recycling facilities, and an openness to innovation and new materials. But at the same time, also simplification of material combinations is needed, just to pinpoint a few issues.”

To Summarise…

Circular plastics - it’s definitely a space to watch over the next few years. Alongside the PPWR and incoming legislation, on top of an already innovative sphere we predict an onslaught of ongoing innovation.

Elizabeth Staab leaves us with firm last words, “I’m a strong believer in innovation, and I really do believe that with collaboration, we will be able to crack this and achieve a circular economy when it comes to packaging here in Europe.”

Watch this space.

PODCAST

Circular Plastics

with Elizabeth Staab from

H.B. Fuller’s Global Packaging Sustainability Manager, Elizabeth Staab, sits
with Libby Munford, Editor, Packaging Europe in the pioneering podcast of our
‘Topic of the month’ series.

Circular Plastics is our focus - we talk strategic challenges, PPWR guidelines and deadlines, recyclability standards and recycling infrastructure, staying one step ahead, and how we can work together across the value chain.

New ALPLA plant brings design, development, and production to Thai customers

At its new plant in Thailand, ALPLA will collaborate with customers to design and develop packaging products, utilizing one-step injection stretch-blow and injection moulding to produce plastic bottles, preforms, matching closures, and more.

Located in Chachoengsao, near Bangkok, the 24,000 square-metre building serves as a new location for production and administration. ALPLA intends to produce a range of injection-moulded packaging parts at the site, making use of its newly introduced injection moulding and one-step injection stretch-blow moulding technologies.

However, the site also features a technical centre for product development – as well as the region’s first STUDIOa ‘one-stop-shop’ for designing ‘safe, affordable and sustainable full-system solutions made of plastic’ alongside customers.

“The all-in-one concept strengthens our leading role as a system provider for safe, affordable and sustainable plastic packaging from a single source,” explains Roland Wallner, ALPLA’s managing director Region Asia Pacific (APAC). “Chachoengsao combines technological diversity, the highest quality and customer service under one roof. In this way, we wish to expand our market share and unlock new segments.”

The site’s production lines have been producing in series since the start of 2025, and the new location is set to increase ALPLA’s production capacity and, in turn, its presence in Southeast Asia. Its placement in the Bangkok metropolitan region is set to bring ALPLA in closer proximity with its customers and optimize connections.

Chachoengsao will replace ALPLA’s first Thai plant in Prachinburi as the company’s headquarters, and the later will be dedicated entirely to extrusion blow moulding in the future.

“Our involvement in Thailand more than 20 years ago represented the start of our activities in Southeast Asia and is still central to our growth today,” says Philipp Lehner, CEO of ALPLA. “The flagship plant in Chachoengsao covers all the needs of our customers and unlocks new opportunities in the market.”

“In Thailand, we are also growing together with our customers,” adds Daniel Qiu, general manager Thailand at ALPLA. “With two high-performance production plants and the recycling plant, we are securing the long-term supply of sustainable packaging solutions and strengthening the nationwide circular economy.

“ALPLA now also offers added value for better products with STUDIOa as well as the technical centre. The innovative one-stop-shop for product design includes customers right from the development phase and creates more sustainable packaging thanks to lightweighting and design for recycling.”

Back in 2022, ALPLA formed its Asia-Pacific operations by consolidating its business in Southeast Asia and China

It also entered into a joint venture partnership with PTT Global Chemical to expand in the recycling space; apparently, their joint state-of-the-art recycling plant ENVICCO in the Rayong province produces 30,000 tonnes of food-grade recycled PET material and 15,000 tonnes of recycled HDPE material every year.

In a more recent development, ALPLA has acquired a majority stake in Clean Bottle; its plant in São José dos Pinhais reportedly comes with an annual capacity of 15,000 tonnes of rHDPE, which ALPLA hopes to utilize to supply recycled packaging on South American markets.

A Memorandum of Understanding between Dow and SCG Chemicals also aims to process an annual 200kt of plastic waste in the Asia Pacific region by 2030. The partnership’s initial phases will focus on waste sorting, mechanical recycling, and advanced recycling in Thailand, with plans to source plastic waste feedstocks in China, Korea, Japan, Taiwan, Australia, and New Zealand in the future.

Playbook lays out guidelines for mechanical recycling of mixed plastic waste 2

In its new Solution Model playbook, the Alliance to End Plastic Waste outlines its approach to converting mixed plastic waste into products of value – keeping investment and technology requirements minimal to ensure its accessibility for countries with less developed recycling systems.

The first two playbooks – Engaging Households in Segregated Municipal Waste Collection and Unlocking Value Through Basic Manual Sorting of Municipal Waste – were developed alongside Boston Consulting Group and released in March 2024.

Now the third instalment, Capturing Value Through Basic Mechanical Recycling of Mixed Plastic Waste, outlines the ways in which mechanical recycling can utilize ‘simple’ technologies to convert waste into furniture and basic construction materials.

Mixed plastic waste streams are reportedly difficult to recycle economically, so the playbook examines what the Alliance considers to be easily scalable, low-technology methods for converting mixed-waste streams into usable products and keeping recovered plastic in circulation. It prioritizes collection, processing and converting as key components of the value chain, ensuring that recycling feedstock is supplied consistently.

Apparently, turning waste into products with market value keeps plastic waste out of oceans and landfill, cuts down on plastic pollution rates, and establishes a circular, closed-loop system. The process is thought to create jobs and stimulate local economies without requiring excessive initial investment, keeping it accessible to small businesses and low-income regions.

The Alliance explains that its model is informed by projects implemented in Costa Rica, Ghana, South Africa, the USA, the Philippines, and other regions. Challenges, lessons, and enabling conditions for success are all recorded in the playbook.

Its findings are predominantly aimed at countries in the early stages of waste management maturity, namely those classified in Categories I, II, and III under the Plastic Waste Management Framework.

Such categories encompass nations operating under limited or no management regulation and infrastructure; and those dependent on waste reclaimers in an informal sector and recycling systems with smaller entrepreneurs at the helm, taking advantage of ‘niche market opportunities’.

Nevertheless, countries with more advanced waste management and recycling systems can also utilize these solutions.

“Tackling plastic pollution requires a multifaceted, multistakeholder approach,” said Alliance president and CEO Jacob Duer. “Solution Model playbooks are aimed at improving the understanding of the many stakeholders across the plastic value chain about what is possible and what else is needed to drive systems change to end plastic waste in the environment and develop a circular economy for plastics.

“Our hope is that the playbooks will encourage other organizations to scale and replicate these solutions, as we seek a wide range of partners to accelerate the achievement of a circular economy that transforms plastic into a sustainable material.”

Arun Rajamani, managing director and partner at Boston Consulting Group, added: “Speed, efficiency, and scalability are critical to addressing the challenges of plastic waste management, especially in the face of rising global plastic consumption.

“At BCG, we are committed to advancing sustainability and circularity, which is why in close collaboration with the Alliance, we applied our expertise to help design, document, and disseminate these Solution Models.

“We hope these playbooks, enriched with practical insights, lessons learned, and real-world examples, will empower stakeholders to strengthen recycling systems and accelerate progress toward a circular economy.”

In similar news, Packaging Europe has published its own guide to tackling the 335+ million tonne increase in Africa’s plastic waste throughout the last fifty years, consulting the expertise of the African Circular Economy Alliance, Circularium Africa Advisory’s Clem Ugorji, the Aga Khan Fund for Economic Development, and more.

Two guides were also created last year to help develop and achieve food safety guidelines for the Mongolian food sector, stemming from a project completed by the World Packaging Organisation and the United Nations Industrial Development Organization. The guides were modelled on international best practices and the Food and Agriculture Organization’s Codex/CAC/RCP 1-1969 food hygiene principles.

Members of the Alliance to End Plastic Waste were caught up in controversy late last year as Unearthed, an independent journalism team at Greenpeace UK, accused them of producing over 1,000 times more plastic than they cleaned up in its first five years and engaging in ‘greenwashing’. The Alliance argued that there was ‘no factual basis’ for these claims.

Polystyrene mechanically recycled into yoghurt cups in supermarket ‘first’

INEOS Styrolution has completed a collaborative project to mechanically recycle polystyrene into yoghurt cups, set to hit Lidl supermarket shelves early this year.

Registered as a novel technology in line with EU 2022/1616, INEOS Styrolution’s “super clean” purification process is believed to result in recyclates that are suitable for food contact – a process that was previously limited to PET bottle recyclates, the company says.

It involves multiple steps ranging from deep NIR sorting, including object recognition, through to hot washing, flake sorting, melt filtration, and pelletizing.

Reportedly, the recycled material provides the same physical properties as conventionally produced polystyrene. INEOS Styrolution claims that the material and resultant cups have undergone ‘intensive’ quality controls, as well as ‘detailed’ analyses to complete an EFSA evaluation.

It is also believed that the environmental footprint of a recycled cup would be ‘significantly lower’ than that of a conventional polystyrene cup.

In spring 2024, dairy manufacturer Unternehmensgruppe Theo Müller worked with INEOS Styrolution on an initial consumer test to gauge consumers’ perceptions of cups containing recyclate. An INEOS canteen distributed ‘several hundred’ yoghurt cups made of recycled polystyrene to volunteers.

90% of testers said they would buy the product, while also accepting that a recycled cup could appear in different colours to the plain white of virgin polystyrene.

“Polystyrene arrived in the champions league of recycled food contact materials,” explains Dr. Frank Eisenträger, ECO & market development manager at INEOS Styrolution. “It will enable producers to meet the new requirements of the new EU directive PPWR for packaging and packaging waste.”

Lena Lembach, senior packaging development at Unternehmensgruppe Theo Müller, adds: “This is a milestone achievement on our common way to perfect circularity for polystyrene cups and towards fulfilment of the PPWR requirements as well as our own CO2 footprint reduction targets.”

"This is a milestone achievement on our common way to perfect circularity for polystyrene cups and towards fulfilment of the PPWR requirements as well as our own CO2 footprint reduction targets.”

Back in the summer of 2023, INEOS Styrolution worked with TOMRA and EGN Entsorgungsgesellschaft Niederrhein to open an advanced mechanical recycling facility; the partners planned to convert an annual 40kt of post-consumer polystyrene into recycled polystyrene for food packaging. The plant would also utilize the “super clean” process.

Additionally, a form-fill-seal yoghurt pot containing 98.5% polystyrene was previously developed by Plastiques Venthenat, Amcor, Olga, Cedap, and Arcil-Synerlink in hopes of streamlining the sorting and recycling process. It was subsequently nominated for a Sustainability Award, and became one of two winners under the Pre-Commercialized Recyclable Packaging category.

Earlier still, COEXPAN’s innovation and technology centre, INNOTECH, completed a trial to source polystyrene grade from household food packaging waste and use it to produce yoghurt pots.