PROCESSING | THIN-WALL PACKAGING


a wider range of products, including plastic trash bags, and carry-out bags. As well as laws of


recyclability and labelling, he said other policies are under consideration, including: deposit return systems; single-use packaging bans; material and


product taxes; and advanced recycling (such as chemical or molecular recycling).


Sustainable approach


Above: Berry’s Heinz Snap Pots contain 39% recycled plastic IMAGE: BERRY GLOBAL


Diane Marret, sustainability director at Berry Global, talked about how her company has responded to the two types of legislation – PCR mandates (specifying levels of recyclate in prod- ucts); and EPR laws (shifting the cost of managing end-of-life packaging costs towards brand owners). She said there are 43 active EPR taking place


across 15 states. Recycled content mandates will be part of EPR commitments. “The intent is to improve recycling infrastructure


and improve access,” she said. “This will increase recycling rates and the availability of recycled materials and decrease the use of virgin materials.” At the same time, demand for high-quality, food-safe PCR will continue to increase. Packaging companies need to carry out three


main actions in response: n Ensure that packaging is designed for recyclability; n Incorporate circular materials into packaging; and, n Reduce or lightweight packaging, to lower carbon footprint.


“Don’t wait for the implementation of new laws


– take action now,” she said. “Circular material supply is already limited and legislation will only raise demand and intensify competition.” There are three steps to getting started, she said: evaluate current packaging for recyclability; ensure that any new packaging design complies with legislation; and then validate designs through qualification on pilot and production lines. She said that an option like mechanical recycling was suitable for many applications, but presented some challenges for quality and aesthetics. Chemical recycling can allow offsetting of fossil fuel-based feedstocks – but can be harder to explain to consumers.


She also highlighted a few examples of how Berry had developed more sustainable packaging. In one example, a multi-material canister was converted to an all-PP version that was easier to recycle; drinking cups for Wendy’s were made easier to recycle, saving an estimated 10 million lbs of waste from landfill in two years; and stock PP containers incorporated 10% bio-circular material, derived from cooking oils.


Moulded fibre thermoforming on the rise


While moulded fibre is not an extrud- ed plastic, it has risen to become a potential rival to thermoformed plastic parts in some applications. Some companies, such as Kiefel,


even offer machines to process moulded fibre alongside its portfolio of thermoforming machinery. Larry Hutchinson, global market development manager for food packaging at Solenis, told delegates that moulded fibre accounts for nearly 5% of ‘paper and fibre’ packaging. Nearly 40% of moulded fibre parts are effectively thermoformed, he added. The global market for moulded


fibre packaging is projected to double over the next five years, he said, with most growth coming in the Asia-Pacific region. The most common end-use will be food and drink packaging.


14 FILM & SHEET EXTRUSION | November 2023 www.filmandsheet.com


There is still work to do on the technology, he said: at 60°C, for instance, he said oil penetration took 120 minutes. Regarding water penetration, wet moulding was “essentially bulletproof”, he said, while dry moulding was “acceptable [with] further development needed”.


He cited some advantages of moulded fibre as: PFAS-free; many material sources; and recyclability. Regarding composting, he said individual assessment was needed for most industrial composting, while home and backyard composting could not yet be confirmed by testing.


Left: In addition to its conventional plastics machinery, Kiefel offer machines to process moulded fibre


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IMAGE: SIEMENS


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