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Day 31: Dec. 8th, 2009

Posted by Chandler Slavin on Oct 16, 2012 10:31:00 AM

Good day!

It’s official—I am going to Ontario next week to participant in a Committee that looks to find a way to recycle thermoforms! I am totally tickled pink by this news; I will keep you all posted!

And guess what: this is sort of funny, well not funny, but something to note…Some of my research on paper versus plastic in the context of sustainability was distributed to the members of the Committee as pre-reading material and a member voiced concern that this research favored plastic over paper; therefore, my research was removed from the list of pre-reading material because this Committee looks to be unbiased, and my research was very pro-plastic. 

While I do admit that it does make an argument for plastic over paper, all of the information is referenced and from publicly available records via the EPA and other environmental agencies. Moreover, I believe that the best way to understand a concept/situation/problem/topic is to understand ALL the different arguments; therefore, I would love to see a pro-paper argument, a pro-plastic argument, and any other argument that would inform discussion on packaging and sustainability. Perhaps I am still clinging on to the classroom etiquette where every argument is valid if supported with facts, regardless of if it is biased. I was always taught that it was my role as an academic to identify people’s objectives/biases in order to fully understand the argument (we live in a post modern world where one’s social location informs their perceptive). As a plastics girl, I obviously have a goal to make people understand that plastic IS NOT BAD; it just gets a bad rap in the eyes of the public because of lack of education and poor marketing. Therefore, my research on plastic and paper was more of an “in the defense of plastic” piece as everyone, even my college buddies, think plastic is bad and paper is good because plastic comes from oil and paper from trees.

On that note, check out this blog post from the Nashville Wraps Blog; it is all about recycled paper and it’s often times ethically-compromised point of origin: http://www.nashvillewrapscommunity.com/blog/?p=1275.

This is a great blog, by the by. Check it out!

Okay, shall we resume our recycling narrative?

Where were we…

On December 8th I arrived to the office feeling a little unmotivated; I still had not received the results from our RPET samples’ “test” via the MRF’s optical sorting technology and my Superior told me to shelf the recycling initiative for a bit because it wasn’t an economic priority for Dordan. So, while I waited for the results and my enthusiasm to return, I focused on other sustainability concerns. One of which is the life cycle impacts of recycled PET. After all, my clamshell recycling initiative is all about RPET and increasing its feedstock via the incorporation of RPET clams into the PET-bottle recycling infrastructure…love me my RPET. At the same time, however, I couldn’t find any industry data about the energy required/GHG emitted during RPET production to validate that RPET was the route we wanted to go as a sustainable plastics company.

I shot my contact at an industry-working group the following email, hoping he could provide some insight:

Hello!

Hope your having a lovely in-between holiday time.

In regard to COMPASS, the environmental packaging assessment tool created by the SPC: I am trying to utilize the software to compare a corrugated package of similar dimensions with a plastic package. The plastic package is RPET with a certified minimum of 70% PCR but I am unable to input this into the software. I know you had explained that this is because there is no industry data about RPET available at this time; my question, however, is how can that be when RPET is the new “hot” material in the professional packaging world. How can you have data on PLA and not RPET? When will this material be available for selection within the softwar

Thanks for your time!

And his response came later that afternoon:

Hi Chandler,

PCR is a funny thing. The marketplace has run head first to incorporate recycled content, yet the industry associations have not released any of the LCI data for folks to use for comparative purposes. These LCI data do not come from entities like GreenBlue, but from companies that make the materials. NatureWorks released the data for PLA because it was in their interest to show their product to have a better environmental profile than other traditional polymers. But, the rPET folks have not released the requisite data. Makes you wonder if the profile for rPET is really as good as we assume. Neither USLCI nor ecoinvent have such data, so we are unable to model r-anything yet.

I was at the LCA conference in Boston and the noise was about new data points. ACC – the folks who have the plastics data, intend to release them, but no eta. Unfortunately, data are the limiting factor to environmental assessment and will probably be that way unless there is some kind of legislative push or some other incentive that could induce industry to release data. Everyone (us and all other LCA practitioners) are waiting on LCI data. There aren’t even good proxy data that we can use in the meantime.

Hope that helps.

Later I found this article in Packaging Digest, which provides further insight into the RPET “situation:”

The need for data grows as PCR content becomes more common

Given the popular consumer perception that packaging is wasteful, there is an intensive effort to improve packaging performance and recoverability, with manufacturers evaluating material and design alternatives to differentiate their packages on-shelf. Recycled content appeals to consumers and directly responds to concerns of packaging waste. Brand owners are testing ways to incorporate post-consumer-recycled (PCR) content into packaging where virgin material had been the norm.

Packaging developed with recycled polymers has been particularly in demand. Increasing recycled content across the packaging spectrum is perceived to have enhanced environmental profiles over virgin-content counterparts. In many instances, this is true, particularly with plastics, but it's often hard to quantify these environmental benefits due to a lack of data for recycled materials.

Life-cycle assessment (LCA) methods can help quantify the benefits and illuminate tradeoffs of virgin and recycled materials. Yet a methodology is only as accurate as the data collected. There are hundreds of industrial processes that contribute to the creation of a single package. The LCA methodology requires detailed data about all the processes that go into bringing a packaged product to market, not just the obvious ones.

Enterprising companies have made great strides in introducing packaging with a high percentage of PCR content, even for food contact applications that have stricter regulations. Many of these innovations can be attributed to leader companies that have set up unique relationships for material collection and conversion to produce a small set of products.

These companies have made significant investments and are paying higher prices to produce packaging with green attributes. However, to accurately communicate what the environmental benefits are, manufacturers need to be able to quantify the specifics of the environmental advantages of using PCR content in terms of greenhouse gas emissions, material usage, water consumption and other environmental metrics.

Using LCA methodology to compare a recycled plastic package with a virgin one will allow companies to credibly quantify a package's environmental savings, as well as justify the investment in PCR materials. Yet one needs life-cycle inventory (LCI) data, or the inputs and outputs for the entire life cycle for both materials, to make these calculations. LCI data are essential not only for assessing packaging applications, but also for all sorts of product development that uses the same commodity materials. The requisite LCI data for some virgin materials are publicly available, though some are outdated or incomplete, and we have a reasonable understanding of the various human and environmental impacts associated with their production and use. Unfortunately, the same kind of detailed and current data for most recycled forms of the commodity materials used in packaging are not yet publicly available. Efforts are underway to ensure the data for recycled materials become publicly available. Until then, the lack of LCI data for many commodity materials is a serious impediment to measurable progress along sustainability goals.

This article is accessible at: http://www.packagingdigest.com/article/447099-The_need_for_data_grows_as_PCR_content_becomes_more_common.php?rssid=20535&q=minal+mistry.

Hmmm…time to speak with our material suppliers of RPET to see why they haven’t released any LCI data…looks like we are about to travel into “proprietary” waters again; great.

Tune in tomorrow to get the much anticipated results of our RPET samples’ “test!”

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Day 30: Dec. 1st, 2009

Posted by Chandler Slavin on Oct 16, 2012 10:29:00 AM

Hello! Sorry I didn’t post yesterday! I am now a new resident of the West Loop, Chicago. Moving yesterday was a total debacle: movers came early, I didn’t have enough boxes, I got lost on the way to my new place and ended up too far West for one’s own good, and then I got locked out of my new place and had to call a lock smith. Fun times…

Well I’m back and ready to talk about recycling in America!

Where were we?

Two days later I arrived to the office anticipating the results of our RPET samples’ “test” to determine if our RPET is “read” like bottle-grade PET. Here’s the thinking: If our RPET moves through the MRF’s optical sorting technology like PET bottles, then we would have some leverage to approach our suppliers of post consumer regrind PET with and suggest they accept bales of PET bottles with our RPET thermoforms in the mix. It’s worth a shot, right? I swear, as this recycling initiative moves forward it keeps changing. For those of you who are new to my blog or have not followed the narrative, these are some possible solutions to finding a way to recycle thermoformed packaging:
    1. Integrate our RPET thermoforms into the existing PET bottle recycling infrastructure. This is large scale and regionally a-specific.
    2. Work with our supplier of PCR PET to create a pilot program that works as follows:
  • We would work with WM to designate a bale for PET bottles AND RPET thermoforms (either just our packages, so we could certify the integrity of the resin feedstock, or all RPET thermoforms, which may get a little messy depending on which domestic/international markets said material is originating from);
  • This bale would sit at WM collecting PET bottles and RPET thermoforms until full;
  • This mixed bale of RPET thermoforms and PET bottles would be purchased by our material supplier who would clean, grind, and extrude the mixed bale to create sheets for us to thermoform;
  • We would ensure that we would buy this mixed thermoform and bottle-grade RPET sheet, providing security for the material supplier to engage in this initiative;
  • We would test this mixed sheet with our machines and see what the output is.
  1. Create a new end market for low-grade, mixed rigid plastic packaging, as is the case in some communities on the East and West coasts where all plastic, once the PET bottles and HDPE jugs are removed for recycling, are collected for reprocessing. Sometimes this reprocessing manifests itself in lumber applications and sometimes this low-grade plastic mix is sold to international markets for WTE or perhaps feedstock for resin production.
So yeah…don’t really know what the best approach is…any suggestions?

Now that we have recapped, let us return to December 1st, 2009.

Upon arrival to the office I shot my contact at WM the following email:

Good day!

I hope you had a lovely Thanksgiving weekend.

I just wanted to drop you a quick email inquiring into the status of our samples’ analysis via optical sorting. At your earliest convenience, please let me know if you have received the status of said analysis.

Thanks again for your time; I owe you lunch!

Best,

Chandler Slavin

Later that day I received the following response:

Hi Chandler,

Thanks for the note, yes, it was a nice Holiday break. I will reach out to my contact and our Grayslake plant manager this week to see if there's any update. The big issue as I think you know is on the buyer's end....even if WM can accept and sort your PET material, the buyer's of PET typically only recover the bottle grades, any other plastic is typically discarded. 

TICK TOCK.

Tune in tomorrow to learn more about recycling in America!

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Day 29: Nov. 30th, 2009

Posted by Chandler Slavin on Oct 16, 2012 10:28:00 AM

Happy Monday Funday! Sorry I didn’t post on Friday—I actually had a presentation at one of our customers’ company about packaging and sustainability and then I got sick! My tongue was green and had these giant balls at the back of the throat, which was super weird. It turns out I have had a low-grade infection for two weeks, ug! This working full time+moving+having a social life is really starting to take its toll. I got quite the lecture from my boss/father about “burning the candle at both ends” so basically if I miss another day because I am sick I get in super duper trouble. Yikes!

Shall we resume our recycling narrative?

Several days later I received an email from Robert Carlson of the CA EPA:

Chandler,

I may or may not have mentioned to you that my wife is a career counselor and she does some work with “Green Careers”. Well, she is doing something right now about “infusing green” into your job. Basically what to do to make what is typically not a “Green” job into a green job.

I thought of you, an account executive at a plastics manufacturing company working to green the company! Perfect fit, right? Plus I thought you told me that you sort of created the position of sustainability director yourself…So how much more “take charge” can you get, right?

Anyway, she may be contacting you to ask you a few questions about how you went about it, things you thought worked well and things you found challenging (or something…I’m not really sure where she’ll be going) if that’s alright.

Wow! Rad! Someone wants to interview me about my work at Dordan? SPLENDID!

I spoke with Robert’s wife later that day; she is a doll!

Hey!

I just got off the phone with your wife; she has a lovely phone personality! Our conversation got cut off, however, as my phone interviewed called in. I asked if she wanted me to provide her with an abstract, per se, of our conversation and she agreed. The email she provided, however, may not actually be her email, as it sort of got jumbled in the end. If you could see that she gets the following abstract, I would really appreciate it.

How Dordan is “infusing” green into our company:

I work for a mid-western based, custom-design thermoformer of plastic non-food packaging. Currently, no plastic packaging is recycled in the US, aside from PET beverage bottles. I am working with various contacts at WM to find an end-of-life market for our plastic packaging materials. This is an on-going effort, and having spoken with the Environmental Director at Starbucks who implemented a pilot recycling program for their paper cups in several NY Starbucks’ stores, I am finding it increasingly difficult to create a new recycling market, as the economics don’t seem to support it. In other words, there are many people one needs to get on board to ensure a new end-of-market for materials not currently recycled, and I don’t believe that we have the power to make those various players participate without some kind of incentive on their part. Regardless, I am committed to finding a way to reuse or recycled our plastic packages. It can be done; it just has not been done. Hopefully through the vehicle of supply chain collaboration we will be able to create either a new market for our packages post-consumer or integrate our PET packages into the existing PET bottle recycling infrastructure.

I am also working with various representatives from greenerpackage.com in regard to their packaging supplier database, which is intended to eliminate green-washing. I feel as though this web-site is committed to sustainability in packaging and I look forward to my continued involvement with them.

I persuaded my company to become a subscriber to the Sustainable Packaging Coalitions’ comparative LCA assessment tool COMPASS, which has legitimate, third-party peer reviewed LCIA data for various packaging materials, conversion processes, and end-of-life treatment. This tool allows us to determine the green house gas emissions, fossil fuel consumption, etc. of packaging, therefore informing our engineering/R&D teams with the data necessary to design packages that have less of a burden on the environment than packages currently on the market.

Our manufacturing facility has made various sustainable efforts to reduce our processes burden on the environment. One such effort concerns revamping the lights in our factory to consume less energy that the previous lighting. We also regrind our own scrap and sell it back to our material suppliers. I am also investigating a grant for wind-power.

I got my degree in religious ethics with a concentration in social justice and ethics from DePaul University, which has informed how I understand/interpret claims of ethical considerations via the environment. While at times it is discouraging to discover peoples’? true motivation for making green claims, there are those who are genuinely committed to being “green,” outside of any capitalistic endeavor (as in the case with your husbandJ). I hope I did not come off too cynical; I just want to emphasize while everyone wants to do better by the environment, few are willing to pay for it themselves.

I hope this helps. If you have any other questions or comments, please do not hesitate to ask. I hope you are enjoying your job as a career counselor, even in these difficult times.

Best,

Chandler Slavin

Well that was fun!

Tune in tomorrow to learn more about recycling in America!

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Day 27: Nov. 24th, 2009

Posted by Chandler Slavin on Oct 16, 2012 10:26:00 AM

Helllllloooooo world!

I hope everyone had a nice weekend. Chicago was crazy with the Chi-Irish! I left my apartment Saturday afternoon to discover that my street had been taken over by rowdy drunks…good times!

Shall we resume our recycling narrative?

Today’s the day, I remember thinking when I arrived to the office: Today I finally get my much-anticipated phone interview with the Environmental Director of Starbucks about the pilot recycling program he implemented for Starbuck’s coffee cups in several NY stores!!!

Here goes nothing; deep breath.

Ring, ring…

…Thirty minutes later…

Phew. I can stop sweating now. He was super nice, I thought to myself as I looked over the notes I took. While it was still fresh, I compiled the information and sent my team the following email:

Hey guys,

I just got off the phone with the Environmental Director of Starbucks; he was really cool and very insightful. This is what I learned:
    1. Starbucks found a university that creates the standards for corrugated boxes. They then tested their cups with the corrugated to see if it had a positive or neutral effect on the fiber. To their delight, the university determined that the cups actually yield a positive value on the fiber feedstock because of its high quality composition. In other words, the cups strengthened the OTC.
    2. They then found Pratt Industries, which is a cardboard manufacturer from Australia who is trying to make in inlet into the North American market, to process their cups with the corrugated material.
    3. They made a donation to Global Green, which is an NGO who created the CORR project, which looks to reclaim corrugated material. Upon their contribution, they had access to all of their research and contacts within various municipalities.
    4. From there they set up a store trial, where they had their customers separate the cup from the lid, to be collected in the warehouse of a MRF until the quantity necessary to find an end market accumulated. Their customers were happy to do this because they have been asking for this for a while.
    5. They focused on expanding the existing OCC recycling infrastructure, not creating a new market or closed loop system. They opted for the OCC market because most communities have access to these programs because corrugated is one if the mostly recycled fiber materials (OCC market as opposed to the mixed paper waste market, which is much more regionally specific, as is the case with the markets for mixed plastic waste that reside predominantly on the East and West coasts for shipment to Asia for energy recovery via incineration).
    6. They then plan to use the pilot project as a case study for why more buyers of OCC from MRFs should accept Starbucks cups on the bales.
    7. They held a cup summit and because of their large pull in the market place, were able to invite powerful players in various municipalities, resin manufacturers (Dow), retailers, MRFs, etc. to create a momentum that cities would like to tap into for their own PR initiatives (municipalities compete with how much material they are saving from landfills i.e. “zero waste” PR).
*Basically, if there is enough volume of any reclaimed material, there can be an end market for it. This implies that we must collaborate with North American manufacturers of thermoformed non-food plastic packaging in order to find the quantity necessary to find a buyer for the end-of-life market.

I know this is not on the top of our list of priorities, but it is a good long-term goal. Until the market picks up, however, I find it difficult to imagine that our competitors would want to engage in this type of recycling initiative. Moreover, we are not Starbucks, so spear-heading something like this on altruism alone probably won’t take us very far. I honestly think that collaboration is the way to go…

We are still waiting to hear back the results from the MRF to see if our RPET is compatible with the PET bottles via optical sorting, If so, we have already tackled one of the components of the above ?approach. I think that we should continue to find ways to enhance the existing infrastructure; all we need is collaboration to produce the quantity necessary to find an end-market for it.

I’ll keep you posted!

Chandler

Tune in Wednesday to learn more about recycling in America!

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Day 21: Nov. 7th, 2009

Posted by Chandler Slavin on Oct 16, 2012 10:10:00 AM

After sending out several emails to contacts in different organizations (who wish to remain anonymous), I received the following information about non-bottle PET recycling. Hopefully you will find this information as valuable as I did in my journey to discover why PET clamshells, blisters, trays and components are not recycled in most American communities.

Quick answers:
    1. Including blister packs into PET bottle recyclate is unlikely to be good idea;
    2. Clear PET trays might be technically okay to be mixed in with PET bottles – but there is a sorting problem due to PVC;
    3. PET trays/clamshells/blister packs could be sorted out of the residual mixed plastics waste to make an rPET grade – although this may prove to be more restricted in markets than bottle recyclate.
PET types

Blister packs that aren’t PVC generally use a copolymer of PET called PET-G or PETG. This is softer and tougher than standard PET and can’t crystallize, so is used for some PET films and thin sheet applications because the manufacturing is easier (even though the material is a bit more expensive). ?Some clamshells and trays use PET-G, but most will use standard PET identical to that used for bottles. All ovenable frozen food trays use crystallized PET as they need to stay rigid at high temperature – this is chemically identical to bottle grade, but most frozen food trays are pigmented anyway?

PET-G can be a problem in PET recycling. A little bit probably would never be noticed, but if significant sources of PET-G were going to be used as feedstock for any particular process, this would have to be fully tested in trials by the re-processor and the end-users – recyclate for use in bottles (made by injection stretch blow molding) might not be able to accept much PET-G without quality problems, but a recyclate intended for trays or clamshells (made by sheet extrusion and thermoforming) might be fine.

PVC Issue

Getting PET packages recycled also depends on the confidence and cost of being able to extract the PET from the commingled plastics without excessive PVC contamination, which degrades at PET processing temperatures (causes yellowing, black specks and may affect food-contact status)

Since clear PVC is widely used in these sort of packages as well as PET and the two are visually indistinguishable except by inspection of the plastics code (if present) then manual pre-sorting and final checking won’t be feasible based on container shape as it is for bottles. Therefore the automatic sorting would have to start from a very high contamination level– this increases the difficulty of getting to a low enough level of PVC content.

With PET bottle recycling, it is already a little difficult to keep PVC low enough, as PVC gets into the bottle stream anyway in the form of labels and cap liners – if you tried to include trays etc, then only a few PVC packs would need to sneak through the sort process to downgrade a batch.

Hence, recyclers are hesitant to include PET clamshells, trays etc with sorted PET bottles because they might end up with lower incomes despite the higher volumes.

All this means to me that it is more sensible to try to get PET clamshells and trays from the mixed plastics fraction (after already removing bottles) and finding a market for that quality of rPET, rather than trying to sort bottles and clamshells/trays together. This is the approach being tested by WRAP (Nextek are running a project for them).

Okay…so based on this insight, it is more feasible to create a new end-market for mixed rigid plastic material than to try and integrate our PET packages into the existing PET-bottle recycling infrastructure…

That’s all for today folks; I think we should all let this information sink in. Tune in tomorrow for more discoveries about recycling in America!

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