How does the recycling value chain work?

In part three of Recycling Spotlight, we go behind the scenes of the recycling process to examine what happens once consumers have done their bit.

We have already discussed the importance of communication in boosting recycling from the consumer end. But what happens after a pack is disposed correctly? The answer depends on the type of pack and where it is being recycled. Put simply, there is no one correct way to recycle as long as the materials are being reused maximally. Here, we will discuss aseptic cartons, which often come under fire for allegedly being difficult to recycle.  

So, what is the ground reality?

Recycling an aseptic package usually requires an additional procedure when being processed, as outlined in the 5-step process. Recycling facilities around the world, both private and public agencies, have been stepping up to make the process simpler. Industry-wide collaborations like Carton Council and the Alliance for Beverage Cartons and the Environment (ACE) are playing their part. As per latest figures, 51% of cartons are being recycled in EU and ACE has the goal of reaching 90% collection and 70% recycling by 2030.

Theoretically, the recycling value chain is straight forward but practically, the execution differs across the globe, especially in the first two steps. 

Step 1: Collection

Used aseptic cartons are collected through recycling programs or drop-off centres. This is the most critical step of the value chain as the prerequisite to recycling. In EU and the Americas, kerbside recycling has become the norm while in Brazil and India, public-private partnerships have been undertaken to ensure effective collection.

Step 2: Sorting

The process at this step varies widely. In certain regions, it is done manually offering gainful employment to the locals. And in other cases, near infrared technology sorts the different types of packaging based on the way they reflect light. This is an especially popular technology for sorting high volumes of packaging materials.

Step 3: Transportation

Once the packages are sorted, they are usually baled and transported to the facility where the packs will be processed. This is an optional step in the chain as many a times, the processing and sorting are done at the same place.

Step 4: Processing in more ways than one

The most important step of the process, which can differ depending on how the cartons will be repurposed and where the recycling is taking place.

A common path forward is to separate the layers of the aseptic packs and use each component separately for different purposes. For this, the cartons are fed into a giant machine called Hydrapulper where water separates the fibrous material of the liquid paperboard from the non-fibrous components, the residual plastic and aluminium, also known as PolyAI. Each component is then further used as raw materials for new things. The paperboard is utilised to create cardboard boxes, tissues, and other paper-based products and the PolyAI is transformed into composite boards or other new products.

Another path is to forgo the separation of components and repurpose the entire carton into new, innovative materials, such as wall panels, building material, and furniture. For this, the cartons are shredded and compressed into different forms using high heat. The plastic in the cartons melts to make the material extra strong and suitable for varied uses.

Step 5: Finding new purpose 

The recycled cartons, be it as separate components or as a composite material, find new life in many forms. In India, used cartons are being repurposed into school furniture whereas Australia has pioneered low-carbon building materials made from aseptic cartons. As the demand for paper-based products increases, food and beverage cartons continue to be a valuable source of recycled paperboard.

The path forward  

Innovation in recycling is growing in leaps and bounds as the industry reinforces its commitment to sustainability. We, at SIG, are launching a new recycling plant in Brazil that will enable polymers and aluminium from used aseptic carton packs to be recovered and sold separately for the first time on an industrial scale in Brazil and is expected to increase the value of the recycled materials by more than 50%..

In the next part of the series, we will look at some of the most innovative recycling initiatives around the world and how they are making a difference. To get that story and more in your inbox, subscribe to the SIGnals Update.