TECHNOLOGY | FILM
maximise value from flexible plastic packaging waste. QRP has been developed following semi- industrial trials by Ceflex consortium companies. Houlder said at the Recycling Flexible Packaging
Above: Ceflex is focusing on many elements to help create a circular
economy for flexible packaging
approach with a focus on the pull from end markets. “A demand-driven process is, we believe, so important in making flexible packaging materi- als sustainable,” he said. By identifying the poten- tial to use recycled materials in different packaging markets, Ceflex is able to work backwards to frame the needs in mechanical and chemical recycling, sorting capacities and collection. There are four key enablers for achieving a
Right: A prototype detergent pack with 35% PCR content derived from beverage carton waste was produced in a partnership between, Henkel, Wentus and Saperatec
circular economy for flexible packaging, according to Ceflex. These focus on: materials, packaging design and end markets; sorting and recycling capacity; EPR systems suited to flexible packaging’s complexity; and a supportive legislative framework. In 2020, the Ceflex Designing for
a Circular Economy (D4ACE) guidelines were published and now a second phase has started which will provide details for the many different designs in flexible packag- ing. “We are working now to actively backfill the data gaps,” said Houlder. In October last year, Ceflex and the Alliance to
conference that QRP is a “clever” process in enabling the creation of valuable streams from mixed waste. For example, transparent films can be “cherry picked” for film-to-film recycling, while pallet film can be sorted and recycled for use in new pallet film or injection moulding compounds. As the input waste materials change, the plant is able to “flex the types of materials it produces, enabling you to valorise as much of the recyclable materials in streams as possible”, he said. Elements of QRP are already being implement- ed by some companies, said Houlder. “We’re hoping this demonstration facility will show the potential to multiply this model, not only in Europe but elsewhere in the world too.” Ceflex had received 20 expressions of interest in
IMAGE: SAPERATEC
the project by December. He said these proposals were being analysed on the basis of showing proof of principle, preferred location and other criteria. Plant construction is under way at another innovative flexible packag- ing project in Europe. Unlike the wide range of packaging targeted by Ceflex, German company Saperatec is focusing on recycling composite packaging using a delamination process to separate the layers. The plant it is building in Dessau will tackle plastic-aluminium laminated packaging and is expect- ed to recycle about 18,000 tonnes of packaging waste per year.
“After years of extensive research and thorough
Right: Saperatec’s delamination process uses separation liquids based on different chemical mixtures for different applications
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End Plastic Waste, announced their collaboration on a demonstration plant for recycling different types of flexible packaging, to be built at commercial scale in Europe. They invited expressions of interest from partners in the industry to develop what will be the first-generation ValueFlex facility. The demonstration plant has a planned 50,000 tpa processing capacity and aims to be operational by 2025. “By improving the value and flexibility of sorting
and recycling processes for polyolefin-based flexible packaging, we can support market demand for high quality post-consumer recyclates from mechanical recycling and feedstocks for chemical recycling,” said Martyn Tickner, Chief Advisor for Circular Solutions at the Alliance. The demonstration plant will use the Ceflex
Quality Recycling Process (QRP), a modular and flexible approach to sorting and recycling to
PLASTICS RECYCLING WORLD | January/February 2023
www.plasticsrecyclingworld.com
testing, we are thrilled to be constructing our first industrial-scale recycling plant, which will com- mence operations [in 2023],” said Thorsten Hornung, CEO of Saperatec. “Our goal is to have a true, lasting impact on the circularity of composite packaging materials, which have proven notori-
IMAGE: CEFLEX
IMAGE: SAPERATEC
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