The Authority on Recyclable Plastic Packaging Design
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PE Flexible
(Polyethylene)
- PE flexible packaging formats include bags, pouches, envelopes, sachets, removable lidding/liners and wraps.
- PE flexible films can be single or multi-layered, using a variety of plastic materials including PE of various densities
- PE residential postconsumer film is primarily collected at retail locations, mostly grocery stores, and thus may include a mix of materials including LDPE, LLDPE, HDPE and a growing number of multi-layer packages.
- PE Flexible packaging is most commonly used to protect fast moving consumer goods products, medical and other technical products
- Currently in North America PE is the dominant plastic film collected and recycled into PCR. PP film collection is emerging in select markets.
Base resin is defined as the polymer makeup of the primary body of the package being assessed.
PE Flex Mono-Material
> 90% (by weight) of PE flexible mono-material per ISO 472:2013
PE is compatible with flexible film collection streams and easily recycled into a variety of end use applications. The supply stream includes a mixture of grades of PE as defined by ISO 472:2013 (HDPE, LDPE, LLDPE, MDPE, VLDPE). Special grades of PE available in the industry like plastomers, mLLDPE, ULDPE and others are also included as “Preferred”. The use of PCR PE in all packages is encouraged to the maximum amount technically and economically feasible
> 90% (by weight) of PE flexible mono-material per ISO 472:2014 and contains EVA copolymers where VA < 5% of total package weight
EVA (ethylene vinyl acetate) copolymers are well known in the industry to be compatible with PE and considered preferred when the vinyl acetate percentage is less than 5% of the total package weight
> 90% (by weight) of PE flexible mono-material per ISO 472:2015 and contains polybutene’s < 5% of total package weight
PB (polybutenes) are typically used in small fractions on PE “easy peel” film formulations that are currently recycled in the industry with no adverse effects. For this reason, PB is accepted in the “Preferred” category up to 5% in weight.
> 90% (by weight) of PE flexible mono-material per ISO 472:2016 and contain ionomer copolymers designed for film extrusion < 20% of total package weight
Based on chemical similarity and data evaluated and obtained by the Film Technical Committee, it has been demonstrated that ethylene copolymer ionomers do not affect recyclability performance when used up to 20% in PE formulations.
80-90% of PE flexible mono-materials per ISO 472:2013
Structures with 80-90% PE and copolymers by weight of the total package may present technical challenges for the recycler’s yield, productivity, or final product quality.
< 50% PE flexible mono-materials per ISO 472:2013
> 50% but < 80% of PE flexible mono-materials per ISO 472:2013
Structures with less than 80% PE of the total package will likely affect the overall yield of the respective PE mechanical recycling process and could negatively impact the recycled plastic quality. For that reason they should be tested to determine if they are Detrimental or Non-Recyclable.
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FPE-CG-01 Critical Guidance Protocol for PE Film and Flexible Packaging
Blends, coextrusion or lamination of PE and other resins
Requires Testing
Non-PE layers or blend components at any level (%) require testing to determine the appropriate APR recyclability category. Since these layers are not removed in the film recycling process, they enter the extrusion stage of the process with the base material where they are either melted and blended with the PE or remain solid and are filtered from the melted product. Testing must show that unfilterable layers have no adverse effect on the recycled PE in future uses.
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FPE-CG-01 Critical Guidance Protocol for PE Film and Flexible Packaging
Contains Aluminum
Renders Package Non Recyclable
Aluminum foil can be detected early in the recycling process by metal detectors designed to protect machinery from catastrophic damage. Metal detectors are unable to differentiate between an aluminum foil and a solid metal part, so the entire package is normally discarded rather than accept the risk. If the aluminum foil passes through metal detection, it can be damaging to the extrusion equipment or can quickly clog a melt filter causing a pressure upset which automatically shuts down the process for safety.
Contains Degradable Polymers
Renders Package Non Recyclable
Polymers designed to degrade by definition diminish the life of the material in the primary use. If not removed in the recycling process, these polymers also shorten the useful life of the product made from the recycled film, possibly compromising quality and durability. Degradable polymers include PLAs, PHAs, PHBs, PHVs, PBS, cellulose acetate, starch-based polymers and others.
Contains Paper
Renders Package Non Recyclable
Pulp from paper becomes a water filtration and contamination problem if they are processed through a wet recycling process. Individual paper fibers are very difficult to remove and attach themselves to the film creating specks and irregularities in the products made from recycled film. Furthermore, in either a wet or dry process they degrade in the extruder creating an undesirable burnt smell that cannot be removed from the recycled plastic which limits its end use.
Contains PET
Renders Package Non Recyclable
PET is incompatible with polyethylene and copolymers from the chemical and rheological standpoints. It melts at significantly higher temperatures and it is known to cause film defects (“unmelts”) that compromise film quality.
Contains PVC or PVDC
Renders Package Non Recyclable
PVC and PVDC layers degrade at low temperatures rendering large portions of the recycled PE unusable.
Adding colorant to packaging can impact NIR sortation and color, which both impact the disposition and value of the final recyclate.
Unpigmented (Natural)
APR Design Preferred
Natural material has the highest value as a recycled stream since it has the widest variety of end-use applications. It is the most cost-effective to process through the recycling system.
White, Buff or Light Colors
APR Design Preferred
It is not common for film to be sorted by color in the recycling process. Therefore, the resulting recycled material is a blend of all the colors present. Light colors typically blend well with little effect to the overall color.
Dark Colors
Detrimental to Recycling
It is not common for film to be sorted by color in the recycling process. Therefore, the resulting recycled material is a blend of all the colors present and darker colors will make a bigger impact on the overall color blend. Since the standard material is a light blend and dark colors are relatively rare, the reclaimer normally hand selects dark colors and processes them separately. In some cases, the dark colors are discarded.
Metallic Pigment
Requires Testing
Metallic film can be detected early in the recycling process by metal detectors designed to protect machinery from catastrophic damage. Metal detectors are unable to differentiate between a metallic film and a solid metal part, so the entire package is normally discarded rather than accept the risk. Testing using Sort S-03 can determine this impact. If the metallic film passes through metal detection, it is then melted and blended with the PE film and can cause material discoloration. There is also some evidence that metallic inclusions can be captured in ultra-fine laser filters and potentially cause equipment problems. Testing using FPE-B-01 and FPE-CG-01 can determine this impact.
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RES-SORT-03a Metal Sorting in the Plastics Recycling Process
Pigmented where density > 0.996 g/cm3
Requires Testing
Many pigments used with PE film are dense and when blended with the polymer increase the overall density of the film. Density is an important property and float-sink tanks are critical separation tools used by film reclaimers. When their weight percentage reaches the point that the film density approaches 0.996 g/cm3, the film should be tested as it may sink in water and in turn become waste at a film reclaimer.
Made with PE flexible material
APR Design Preferred
Since polyethylene flexible is the same polymer as the package body, closures made of it will be captured and processed with the PE film.
Made with PE rigid materials
Requires Testing
Rigid injection-molded attachments are typically produced with low-viscosity (high Melt Flow Index) resins that may impact recycling into films. These attachments to film packaging should be minimized. Testing should be performed to determine the overall impact on the PE flexible recycling stream.
Made with Non PE Flexible or Rigid materials
Requires Testing
Closures enter the film recycling process along with the film they are attached to. When entering the extrusion process they are either melted and blended with the PE film or remain solid and are filtered from the melted product. In order to be considered Preferred, testing must show that the material is either removed from the PE stream or has no adverse effect on the recycled PE films end use.
Made with or contains metal material
Renders Package Non Recyclable
Metal materials can alarm metal detectors that are employed at the beginning of the recycling process to protect machinery. If this occurs, the entire package containing the offending part is discarded and landfilled. In addition, if metal materials happen to pass through the process into the extruder, they can quickly clog a melt filter causing a pressure upset which automatically shuts down the process for safety.
Barriers, Coatings, Additives and Layers are materials added to to the base resin to improve performance such as enhancing the appearance or processability of a package.
Workhorse Additives
APR Design Preferred
Most PE film contains some form of additives but usage should be minimized to maintain the best performance of recycled material for future uses. The following “workhorse” additives commonly used have not been shown to cause significant issues with the PE film recycling process or end use: Antioxidants, Thermal stabilizers, UV stabilizers, Nucleating agents, Antistatic Agents, Antifog Agents, Lubricants and Processing Aids, Slip and Anti-blocking Agents, Fillers, Pigments and Tackifiers.
SiOx and AlOx barrier coatings
APR Design Preferred
Vacuum-deposited coatings like SiOx and AlOx are considered Preferred only when applied directly to PE films without the use of additional wet coatings or primers. These materials are completely inert, non-detectable by any metal detection method used in the recycling industry and deposited as nanometric thin layers on film surfaces, with negligible effect on film density.
Metalized Barrier Layers
Metallized content where surface area ≤ Preferred Surface Area per RES-SORT-03b
Metalized content that is untested or does not pass SORT-S-03
Without further testing, metal content with surface areas above the Preferred Surface Area in RES-SORT-03b are categorized as Non-Recyclable due to a higher probability of being removed by the metal detector during sortation. When packaging is rejected by a metal detector, the package is sent to a waste stream and not recycled.
Metallized content where surface area > Preferred Surface Area per RES-SORT-03b
Metalized film layers can be detected early in the recycling process by metal detectors designed to protect machinery from catastrophic damage. Metal detectors may not be able to differentiate between a metalized film and a solid metal part, so the entire package may be discarded rather than accept the risk. Therefore, metalized content above the Preferred Surface Area specified in RES-SORT-03b need to be tested using SORT-S-03 to verify they are under the spherical equivalent thresholds. If metalized film passes SORT-S-03, it should then be tested using FPE-B-01 and FPE-CG-01 to ensure the metalized content does not negatively impact the final recyclate.
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RES-SORT-03b Metal Decoration Resource
Additives/Barriers with Density approaching 0.996 g/cm3
Requires Testing
Many of the additives and fillers used with PE film are very dense and when blended with the polymer increase the overall density of the film. Density is an important property and float-sink tanks are critical separation tools used by film reclaimers. When their weight percentage reaches the point that the film density approaches 0.996 g/cm3, the film should be tested as it may sink in water and in turn become waste (and yield loss) at a film reclaimer.
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O-S-01 Polyolefin Packaging Articles Sink or Float Evaluation
PVDC Barrier Coatings
Renders Package Non Recyclable
PVDC degrades at low temperatures rendering large portions of the recycled PE unusable.
Additives/Barriers with Density > 1.0 g/cm3
Renders Package Non Recyclable
Many of the additives and fillers used with PE are very dense and when blended with the polymer increase the overall density of the blend. Density is an important property and float-sink tanks are critical separation tools used by film reclaimers. When their weight percentage reaches the point that the blend density is greater than 1.00 g/cm3, the blend sinks in water rather than floats and becomes waste (and yield loss) at a film reclaimer.
Degradable Additives
Renders Package Non Recyclable
See APR Position Paper
Other Additives/Barriers
Requires Testing
A growing number of innovative materials are being used as additives and coatings in PE film packaging. These materials must be tested to determine their impact on PE film recycling processes and the PCR produced.
Labels can interfere with automated sorting as well as impact the quality and quantity of the final recyclate. It is important to consider all aspects of a label such as Surface Area, Substrate, Metal Decoration, Inks and Adhesives when selecting a label.
Surface area coverage is defined as the area of the label divided by the area of the side wall and shoulder of the container. The area of the neck ring, threaded finish and base are not included in the area calculation. The surface coverage area of a label can impact whether or not a package can successfully sorted by NIR and color optical sorters. Label surface area coverage, in conjunction with with substrate, metal decoration, inks and adhesives must be considered when selecting a label.
The label substrate, in conjunction with surface coverage area, metal decoration, inks, and adhesives, must must be considered when selecting a label.
Polymer Film Labels
Made with Polyethlene Materials
Since polyethylene is the same polymer as the package body, labels made of it can be captured and processed with the PE film.
Made with Polyolefin Materials
Polyolefin labels may be compatible with the PE film stream, but require testing to determine their impact on PE film recycling processes and the PCR produced.
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FPE-CG-01 Critical Guidance Protocol for PE Film and Flexible Packaging
Paper Labels
Detrimental to Recycling
Paper labels pulp and become a water filtration and contamination problem if they are processed through a wet recycling process. Individual paper fibers are very difficult to remove and attach themselves to the film creating specks and irregularities in the products made from recycled film. Furthermore, in either a wet or dry process they degrade in the extruder creating an undesirable burnt smell that cannot be removed from the recycled plastic which limits its end use.
Metal Foil Labels
Renders Package Non Recyclable
Metal foil labels can alarm metal detectors that are employed at the beginning of the recycling process to protect machinery. If this occurs, the entire package containing the offending part is discarded and landfilled. In addition, if metal foil labels happen to pass through the process into the extruder, they can quickly clog a melt filter causing a pressure upset which automatically shuts down the process for safety.
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RES-SORT-03b Metal Decoration Resource
Metal decoration on labels includes vapor deposited metal films, metal foils, or inks with metallic pigments. Metal decoration content, in conjunction with surface coverage area, substrate, inks and adhesives, must be considered when selecting a label.
Metal Decoration
Label with metal decoration where surface area ≤ Preferred Surface Area per RES-SORT-03b
Labels with metal decoration that are untested or do not pass SORT-S-03
Labels with metal decoration where surface area > Preferred Surface Area per RES-SORT-03b
Metal decoration on labels above the Preferred Surface Area specified in RES-SORT-03b need to be tested using SORT-S-03 to verify they are under the spherical equivalent thresholds.
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SORT-S-03 Evaluation of Sorting Potential for Plastic Articles Utilizing Metal, Metalized, or Metallic Printed Components
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RES-SORT-03b Metal Decoration Resource
The label inks, in conjunction with surface coverage area, substrate, metal decoration, and adhesives, must be considered when selecting a label.
Label Inks
The use of label inks should be minimized as it may limit the potential reuse of recycled films by negatively impacting film appearance (gels, specks) and mechanical properties.
Any amount of Nitrocellulose Binders
Untested Non-Metallic Inks
Non-Metallic Inks
Non metallic inks require testing to determine their impacts on the recycled PE films. Use FPE-B-01 and FPE-CG-01 to determine impacts.
For inks that do contain metal see label guidance for Metal Decoration.
Direct Print Inks
The use of direct print inks should be minimized as it may limit the potential reuse of recycled films by negatively impacting film appearance (gels, specks) and mechanical properties.
Any amount of Nitrocellulose Binders
Untested Non-Metallic Inks
Non-Metallic Inks
Non metallic inks require testing to determine their impacts on the recycled PE films. Use FPE-B-01 and FPE-CG-01 to determine impacts.
For inks that do contain metal see label guidance for Metal Decoration.
The label adhesive, in conjunction with surface coverage area, substrate, metal decoration, and inks, must be considered when selecting a label.
Label Adhesives
The use of label adhesive should be minimized as it may limit the potential reuse of recycled films by negatively impacting film appearance (gels, specks) and mechanical properties.
Untested Label Adhesive
Tested Label Adhesive
The amount of adhesive should be limited since heavy levels can degrade and volatize in the extruder and may cause gels and specks in the final product even if most recyclers use vented extruders. Large amounts of adhesives can overwhelm the capacity of these extruders to remove the volatile components. Testing using FPE-B-01 and FPE-CG-01 can determine impact and recyclability classification.
Wet Chemistry
The use of wet chemistry materials should be minimized as it may limit the potential reuse of recycled films by negatively impacting film appearance (gels, specks) and mechanical properties.
Any amount of Nitrocellulose Binders
Tested Direct Print Primer, Overprint Lacquers and Coatings
Certain levels of ink components dispersed in the final polymer are thought to be responsible for the grey-green color of recycled PE pellets. The amount of printing should be limited since heavy levels of ink components may degrade and volatize in the extruder, causing gels and specks in the final product even with vented extruders. Large amounts of printing can overwhelm the capacity of these extruders to remove the volatile components.
Untested Direct Print Primer, Overprint Lacquers and Coatings
Tested Laminating/Cold Seal Adhesives
The amount of adhesive should be limited since heavy levels can degrade and volatize in the extruder and may cause gels and specks in the final product even if most recyclers use vented extruders. Large amounts of adhesives can overwhelm the capacity of these extruders to remove the volatile components.
Untested Laminating/Cold Seal Adhesives
Curable inks, coatings and adhesives
Chemically, EBeam or UV curable inks, primers and adhesives are thermoset in nature, not melting with the thermoplastic components of a flexible film, thus acting as a contaminant in the recycling process. Depending on the amount used, they may limit the potential reuse of recycled films by negatively impacting film appearance (gels, specks) and mechanical properties.
Untested Non-Metallic Inks
Non-Metallic Inks
Non metallic inks require testing to determine their impacts on the recycled PE films. Use FPE-B-01 and FPE-CG-01 to determine impacts.
For inks that do contain metal see label guidance for Metal Decoration.