Africa’s first Bottle-2-Bottle plastic recycling plant opens its doors in Wadeville, South Africa

The first Bottle-2-Bottle recycling plant in Africa, with an investment of R75-million and the capability to produce resin that will be suitable for the carbonated drink sector, was officially opened by Minister of Environmental Affairs, Edna Molewa in Wadeville, Johannesburg on Monday, 11 May.
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She was joined at the opening ceremony by notable guests from government and the PET industry including Therese Gearhart, president of Coca-Cola Southern Africa, the joint managing director of Extrupet, Chandru Wadhwani and PETCO, the industry body for PET recycling in South Africa.

The plant, installed by Extrupet, is the first on the continent to use a Coca-Cola approved technology for carbonated soft drink bottles thus enabling the closure of the loop in the biggest sector in the beverage market.

The 3000m² PhoenixPET plant, equipped with Starlinger technology, will supply an additional 14 000 tonnes of PET resin per year to the PET packaging industry. It will eventually divert an additional 22 000 tonnes of post-consumer PET bottles from landfills each year, reducing resource consumption, creating jobs and assisting industry in meeting its target of a 50% recycling rate for 2015.

Cheri Scholtz, PETCO CEO lauds the milestone for the PET industry and says, “PETCO and its shareholders are proud to congratulate Extrupet on the opening of the new plant. We believe it will benefit the local value chain and will ensure the long term viability of post-consumer PET recycling in South Africa.”

She adds, “The cooperation within the PET industry to reach a common goal of integrating recycling into product life cycles is showing very notable results: we have reached a point where 49% of all post-consumer PET bottles are currently recycled – no less than 1.5 billion bottles were recycled in 2014 supporting 44 000 informal income opportunities in PET collection.”

Wadhwani attributes the project’s success to their loyal customers, their shareholders continued commitment as well as the long standing relationship with PETCO and says that the facility has the capability to provide a level of quality assurance to meet the growing local and regional demand in the bottle and thermoforming industry for environmentally-friendly and sustainable packaging.“PhoenixPET is to be viewed as a bench-mark for other recycled polymers as well as packaging mediums aspiring to attain a cradle-to-cradle solution for sustainable packaging.”

The chairperson of PETCO and Franchise technical director of Coca-Cola Southern Africa, Casper Durandt concurs, “We are extremely excited about the fact that South Africa will be the first country on the continent to use PET for Coca-Cola products. We have made every effort to ensure that we maintain the highest quality standards. We thank our partners in PETCO, who represent the full value chain: virgin resin manufacturing, converters, bottlers, brand owners and the retail sector, for ten years of sustained support that has brought us this far. We also thank Extrupet for a great partnership.”

With the Bottle-2-Bottle expansions, it is estimated that an additional 15 000 income opportunities will be created for the informal sector collecting additional material to supply the plant. This supports the green job creation goals entrenched in the National Waste Management Strategy and the Department of Science and Technology’s National Waste Research, Development and Innovation Roadmap.

For more information about the Bottle-2-Bottle initiative, phone Chandru Wadhwani at Extrupet on +27 11 865-8360.

Green packaging shifts up the priority list for brand owners and consumers

By Chris BARKER , 29-Nov-2013

100% recycled packaging logo

Increasing environmental awareness means that sustainable packaging is becoming a higher priority for both consumers and brand owners, as evidenced by the number of cosmetics firms opting for a greener option.

Elizabeth Arden this week chose the Airopack dispensing system, and this adds to the long list of brands opting for environmentally friendly packaging in order to appeal to customers.

The Elizabeth Arden Ceramide products are being produced through the Airopack Full Service Operation, which will see the dispensers produced, filled, sleeved and packed to meet the brand’s specifications.

Increasing awareness

“Brand owners become more aware of their responsibility in today’s society. As environmental awareness shifts higher up the priority list at both consumers and brand owners, sustainable products become increasingly important to express a brand message,” Airopack marketing manager Caren Kuijs tells to CosmeticsDesign-Europe.com

“Over the last 10 years we have identified an enormous growth in cosmetic formulations holding natural ingredients and with this Airopack is able to enhance the total sustaining message on shelf for the consumer.”

This technology has also been adopted by other major companies in the recent past; including Procter & Gamble and Danish brand Nordictan.

As technology advances, lightweight packaging and aerosols with a low carbon footprint and CO2 impact are becoming more practical and are being adopted by larger numbers of companies.

Industry examples

Estee Lauder subsidiary Aveda recently brought a new dimension to packaging by introducing 100% recycled packaging for eye colouring in their ‘Essence of Nature Single Eye Color Refil’ line, launched earlier this year.

The company also adopted the tactic of selling refills of its most popular colors, to allow consumers to re-use the same packaging multiple times.

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Weighing the next 40 years of recycling

Editor’s Note: This story appears in Waste & Recycling News’ commemorative issue, “40 Years of Curbside Recycling.”

Recycling at high-rise apartments offers a great opportunity to collect a large amount of materials from one location, but containers that tenants empty their household bins into can fill fast, especially on weekends.

Instead of toting the potential commodities back to their unit, some residents trash them.

Overcoming the hurdles to convenient recycling at multiple-family housing needs to be addressed, said Steven Thompson, executive director of Curbside Value Partnership, a non-profit group that works with cities and states to increase participation.

“You have to have architects designing multiple chutes on the 30th floor instead of just one for trash,” Thompson said. “That’s going to take a lot of work and a lot of time.”

He hopes it is one of the changes that come about in the next 40 years for curbside recycling.

“There are conundrums the industry doesn’t have its head around, like rural areas,” Thompson said. “It’s very hard to cost-effectively recycle when you have three miles between mailboxes.”

The 40th anniversary of curbside recycling begs the question: What will it be like in the next four decades? What quandaries will be cleared up? What new ones will pop up?

Waste & Recycling News asked some of the leaders in the industry to look into their crystal balls and offer a glimpse of what may be in 2053.

The predictions, aspirations and cautions ranged from boosting the recycling rate beyond 34% to finding profitable solutions to problems and to this warning: Without more attention to quality control during processing, the pendulum could take an ugly swing backward to manufacturers using virgin material.

Steve Miller, CEO of Bulk Handling Systems, sees several trends moving forward, such as more mixing of materials, better technology to extract materials, and higher quality of extracted materials for reprocessing today’s common recyclables.

There will be less left to waste if advances in refuse-derived fuel take some big steps forward in the next four decades, he added. All eyes and many minds are on the organic fraction of the waste stream and anaerobic digestion.

Miller expects the industry to next go after materials like used paper plates, tissues and towels, and plastic films.

“[They’re] not in sufficient quantity to have a commodity value to them but when thought of as an energy source they have a high-caloric value to them and could be utilized that way,” Miller said. “When you go forward I think there will be much more work in that area.”

Contaminated paper products, which can’t be recovered as a fiber source, and other components of the light and high-energy fraction could become a refuse-derived fuel that helps utilities power plants now using coal or natural gas.

Thompson also sees more waste-to-energy facilities on the horizon and his fingers are crossed the option doesn’t deter recycling.

“Waste-to-energy needs to be thought through so it doesn’t become a reason not to recycle,” he said. “People might say, ‘Oh we don’t need to do that. We’ll just burn it.’ There are ways they can co-exist nicely and have a high functionality but it needs to be carefully designed and implemented.”

For now, the industry is stumped as to how to remove the so-called “frozen fuel” of plastic film — grocery bags, dry cleaners bags, and the clear packaging for men’s dress shirts — that gets intertwined with recyclables.

“That material is substantially more than what people think,” said Nathiel Egosi, owner and founder of RRT Design & Construction. “It’s problematic to process because it’s difficult to remove in an automatic fashion.”

Egosi expects those pesky flexible plastic packages to be sorted in some systematic way in upcoming years.

“It’s not a desirable material in bales of plastic and other types of commodities,” he said. “The whole industry is working to develop a technique to get that plastic film out.”

MRFs will evolve to process more materials and do so more economically in the next 40 years, said Bill Moore, president of the consulting firm Moore & Associates. In the 1990s, a big MRF cost $1 million to build and handled 100 tons of material a day; today, $20 million MRFs process 1,000 tons daily, he said.

“I suspect we’ll grow that with more regional facilities,” Moore said. “MRFs will continue to look like sophisticated manufacturing operations. They bring in raw materials and process it. That’s the mindset. They are manufacturers creating value out of product.”

Mick Barry, a board member of the National Recycling Coalition, is rooting for dual-stream recycling to win out over single-stream. He’s concerned about commingled recyclables causing impurity problems with the finished product and turning off buyers.

Barry, who also is a materials broker, points to China’s “Green Fence.” The crackdown on imported waste is more than a short-term awareness campaign about sub-standard scrap, Barry said. He sees it as a long-term, quality-control initiative that affects one of America’s top exports.

There is no longer a ready market in China for impure bales of plastic, paper and other recyclables from the U.S. and Europe.

“We’ve got to clean up our act,” Barry said. “The [United Kingdom] sent too much junk in with plastic and they finally cut the U.K. off. They sent a message to the world: Hey, enough is enough. Don’t dump on us and blame us for being the garbage guys of the world.”

It’s critical that all U.S. recyclers remember their bottom line is creating a raw material from a used material and not simply recovering things from the waste stream, Barry said. His message: Have some pride of ownership.

“If we don’t go back to that, we will lose our position as the primary source of materials for manufacturing product back to the virgin base,” Barry said.

Kate Krebs, a former director of the NRC, envisions a future with no waste at all.

“Waste to me is a design flaw,” she said. “If you design a product correctly, you factor in not only the form and function but end of life. That thinking is permeating through our global manufacturing side. That helps us shift. If we really got the consumer marketing going and we continue to spread end-of-life strategies to the makers of product, looking ahead 40 years we should have a much more efficient, simple system.”

EndInMind Design Launches Unique Way to Encourage Recycling

RecyclerSackOur friend Jay Edwards and his partner Sheila Arora have come up with a cool new way to encourage recycling. They have launched the new EndInMind Design website, endinminddesign.com, and their first new product, RecyclerSack(TM). RecyclerSack is geared toward collecting recyclables, away from home, in places where participation in recycling is low, such as hotels. They have blended the functionality of a plastic bag for segregating recyclables from trash, with fine art, so your recyclables have a beautiful and fashionable place to be stored while waiting for collection.

This is their first product of what is likely to be many, fine art inspired, sustainable solutions. We wish them best of luck and look forward to seeing RecyclerSacks on our next road trip.

Think Green Thursday: Know Your Plastic Facts!

Courtesy of CBS Radio, Houston, Texas

CICELY MITCHELL, CBS Houston
July 18, 2013 12:00 AM

You are always told to recycle your plastic but do you know why it truly benefits our earth to do so?

Check out some of these facts about plastic and the importance of recycling plastic below inside of this installment of “Think Green Thursday”!

1. Did you know that Americans use 2.5 million plastic bottles every hour with most of them being thrown away!?

2. Recycling plastic saves twice as much energy as burning that same plastic in an incinerator.

3. If you choose to throw your plastic bag into the ocean consider this: plastic bags that are thrown into the ocean kill as many as 1,000,000 sea creatures a year. There is a such thing as the “Great Pacific Garbage Patch” that is twice the size of Texas and floats in our world’s water somewhere between San Francisco and Hawaii.

4. If you choose to recycle your plastic, then you are saving three to give times the energy generated by waste-to-energy plants.

5. According to experts, recycling one ton of plastic saves the equivalent of 1,000–2,000 gallons of gasoline!

6. As plastic water bottles are shielded from sunlight in landfills, they will stay there and not decompose for thousands of years!

So think about these facts the next time you are faced with the decision to recycle your plastic or not! Do you recycle your plastic?

Cereal launches in a reusable zippered pouch

Kellogg uses a pouch instead of a traditional bag-in-box format.

By Liz Cuneo, Editor-in-Chief – Food & Beverage Packaging Magazine
July 9, 2013
For the first time, Kellogg is using post-consumer resin in a retail pouch; Kellogg is implementing a reusable pouch for its Kashi cereal from Envision Plastics. The EcoPrime™ pouch is the only FDA-approved, food-grade, recycled high-density polyethylene plastic (HDPE) resin on the market in North America. The pouch is reusable, uses less material than the traditional bag-in-box and is a first-of-its-kind packaging that contains at least 15% recycled material including the first food-safe, post consumer HDPE plastic available. An added consumer perk is that after the cereal is gone, the pouch can be used as a freezer bag for leftovers or to store dry goods because the pouch has a zipper.

Kellogg’s reusable Kashi cereal pouch contains 15% EcoPrime food grade recycled HDPE Resin.

Kellogg’s reusable Kashi cereal pouch contains 15% EcoPrime food grade recycled HDPE Resin.

The main benefit for Kellogg in using EcoPrime™ is the reduction in the use of virgin HDPE. In addition, it ultimately reduces the amount of energy required to obtain virgin petroleum material from the earth. The pouch uses material that was reclaimed from the waste stream, while also providing the barrier needed to protect the food. Kellogg is currently using EcoPrime™ on a variety of Kashi cereals and is evaluating opportunities to expand their use of post-consumer HDPE. Food and Beverage Packaging asked Kellogg for more information about the new pouch and the motivation behind the decision.
Food and Beverage Packaging:  Has Kellogg/Kashi used post-consumer recycled material in the production of pouches before?
Kellogg: No, the new bag for GOLEAN Crisp!™ Cinnamon Crumble and Toasted Berry Crumble cereals is the first of its kind for Kashi as it’s made with post-consumer HDPE—a plastic made with materials reclaimed from the waste stream—rather than traditional HDPE.
FBP: Why did Kellogg/Kashi want to use post-consumer recycled plastic in their pouches?
Kellogg: More than one third of shoppers claim they want environmental packaging, and Kashi has cared about making foods with the health of people and planet in mind for more than 25 years. This new cereal bag offers an environmental benefit and allows us to deliver our foods safely to the consumer. Kashi retailers and consumers recognize and appreciate that commitment.
FBP: How did you start working with Envision Plastics?
Kellogg: Kashi is always seeking ways to improve the health of people and the planet. Through our supplier, we identified the opportunity to use post-consumer HDPE that’s safe for use in a flexible food bag.
FBP: Which Kellogg’s brands will be using the pouches?
Kellogg: We used post-consumer HDPE for a limited run of Kashi® GOLEAN Crisp! Cinnamon Crumble and Toasted Berry Crumble cereals in conjunction with Earth Day.
FBP: Why only a limited run?
Kellogg: We’re evaluating opportunities to use the new bags for other Kashi foods, as well as for our other brands, based on the feedback of our customers and retailers.

Republished from Food & Beverage Packaging Magazine, July 2013
Read the original article here:  http://tinyurl.com/keoru6n

EcoPrime™ Food Grade Recycled HDPE Arrives in Southern California

A crane lowers the EcoPrime vessel through the roof of Envision's Chino California plant

A crane lowers the EcoPrime vessel through the roof of Envision’s Chino California plant

Chino, California – Thursday, June 27, 2013

The final stages of equipment installation are underway at Envision Plastics’ Chino, California operation as a large crane lowered the EcoPrime™ vessel through the roof of the building and into its framework.  The EcoPrime™ vessel is the final component required to allow Envision to produce EcoPrime™, FDA approved food grade recycled HDPE resin on the West coast.

EcoPrime™ is approved for direct food contact in many food and beverage applications under demanding conditions of use.  EcoPrime™ is currently used in packaging for liquid yogurt drinks, cereals, deli foods, nutritional products, food take out containers, personal care products, toys and other products.  It can be used in blow molding, thermoforming, compression molding, film extrusion and some injection molding applications.

Debugging of the equipment and pre-production trials will take place in July.  Production of EcoPrime™ should commence in August.  Stay tuned for more developments.

 

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