Question:  For those who aren’t familiar, what is PCR?

Answer:  Post-Consumer Recycled content, commonly referred to as PCR, is produced from materials recycled by consumers, such as water bottles or other plastic materials collected by local recycling programs or through store drop-off locations. These materials are converted into resin pellets and used to manufacture other plastic products.  PCR is a great way to support a circular economy and reduce the use of virgin resin.

Q: What is the process for converting PCR content into resin?

A: There are two primary methods: Mechanical and Advanced (sometimes known as Chemical) recycling. Mechanical Recycling (mPCR), the most common method, is recycled material is sorted and then mechanically ground up, cleaned, and melted into resin pellets. Advanced Recycling (cPCR) is where the material is broken down at a chemical level to a more basic molecule, then formed into resin pellets.

Q: Is one method preferred over the other?

A: There are pros and cons to each method. Right now, mechanical is the more widely available and energy-efficient method, but the resulting resin may have reduced clarity and performance characteristics than virgin resin. Only certain grades are certified for food contact applications. So, ProAmpac typically would use mPCR at varying percentages to maintain the overall quality of the packaging structure. With Advanced Recycling, the infrastructure to support high-volume production is in the early stages, and capacity is expected to expand significantly in the next few years. cPCR resin performs as well as virgin resin and can be used at a higher percentage without impacting the packaging quality. Food-grade applications are more easily addressed through cPCR, however, cPCR typically requires more energy to produce than mPCR.

Q: What are the benefits of having PCR in your products?

A: Increased sustainability is one of the primary benefits. Many companies have committed to sustainability targets which include decreasing the use of virgin plastic, increasing the use of recycled content, and aiming to make all plastic packaging 100% reusable, recyclable, or compostable. As an example, the Ellen MacArthur Foundation is working with over 500 companies globally to pursue sustainability goals with a target date of 2025. Using PCR content is a key factor in helping these companies achieve those targets. By using PCR content in our manufacturing, we reduce the overall carbon footprint of the packaging. As the recycling infrastructure continues to grow, we can reduce the amount of plastic that winds up in landfills and minimize the future use of virgin resin in our manufacturing process.

Q:  You mentioned that PCR reduces the carbon footprint. How do you determine that?

A:  ProAmpac works with our customers to analyze sustainable options for their packaging structure. Our method is called ProActive CHART, a life cycle analysis tool that assesses the environmental impact of various packaging types. This is a science-based review of greenhouse gas emissions, waste generation, freshwater usage, and other factors. We can run this analysis with packaging structures containing various percentages of PCR content to show the customer how any changes will impact the environment.

Q:  What applications is PCR best suited for?

A:  It is a wide range.  For mechanical, it is typically used for e-commerce mailers, shrink films, and dry foods; however, it can be used elsewhere depending on the application and the percentage of the mPCR content. Since the advanced process produces a resin equal in quality and purity to virgin resin, you can use it in practically any packaging from food to healthcare to industrial applications.

Q:  Can you share any examples of packaging where you have successfully used PCR?

A:  Sure, we had a customer who wanted an increased volume of PCR material for almond packaging while maintaining their food-compliant requirements. We used an FDA-compliant film with PCR content equaling 25% of the overall structure. In another example, we were asked to increase the sustainability of a pet food retort pouch which is a challenging application. By adding PCR to the outer print layer, we met their sustainability target while still being able to withstand high-temperature retort conditions and maintaining the shelf life of the product. In both examples, the packaging maintained the high-quality graphics expected by consumers while meeting all barrier/structure requirements.

Q:  One last question – you mentioned PCR percentages a few times. How is that tracked throughout the process?

A:  There are standards to hold manufacturers accountable for their use of recycled content across the complete chain of custody (from recycling center to resin production to our manufacturing process, etc.). For example, with mPCR, we align with the Recycled Content Certification (RCC). For advanced PCR, we recently received ISCC+ (International Sustainability & Carbon Certification) at two of our facilities (Grimsby, UK; Rocky Mount, VA) which gives us preferred access to the supply chain for advanced PCR resin. To meet sustainability targets, we need confidence in the PCR tracking process, and these standards and certifications provide validation that we are meeting that expectation.