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After being copied on an introductory email to the plastics marketing rep of Waste Management, I called him, hoping he would be able to provide some clarification into why clamshells are not recycled in most American communities.

This is how I summarized my conversation with the plastics marketing rep of WM to Robert:

Hey Robert,

I spoke with the plastics marketing rep from Waste Management about the feasibility of finding a market for non-beverage PET flake (the educational director at WM said that the buyers of PET specify that they don’t want PET clams in the PET beverage bales) and he said that the economics don’t support it. In other words, because of the different properties of the different types of PET (RPET, REPTG, APET, etc.), buyers of balled PET only want bottles as they have the same properties and therefore can be recycled into a new product with the same properties i.e. the green plastic cables that are used to strap components together. Also, the quantity is not there, as in the case with PET bottles, so finding a market for PET clams doesn’t seem possible in this economic environment. However, on the east and west coasts, there is a market for “non-traditional” rigid containers insofar as China will buy them to regrind and make new product.

I feel as though I have been shot! I am cooking up another idea, however, that looks to work with a retailer OR a consumer electronic producer.

The plastic rep from WM said I should look into PLA (he said that it can degrade in a landfill?) or waste-to-energy. I know how you feel about “down recycling” but he told me of a company in Madison, Wisconsin, that takes “non traditional” plastics i.e. films, foams, etc. and blends them with coal to produce steam to create electricity. He said that this is cheaper than landfilling and that the energy is being used to power U of W.

What is a plastic thermoformer to do in order to become more sustainable? Now that I have shelved the recycling idea, I don’t know the next best place to look…

If you have any insight, please let me know!

Again, thanks for all your help; I am very glad I met you!

Oh, the bitter taste of defeat.

The plastics marketing rep of WM is the one who is responsible for finding a supplier and buyer of post-consumer plastic material. Therefore, he is the guy who would be able to explain why there is no buyer of non-beverage PET flake (RPET and PET thermoforms). This is what he told me:

There is no buyer of non-beverage PET flake because no one has every invested the time or money necessary to set up this infrastructure, find a buyer, outline the specs, etc. As WM has become more sophisticated, we have been able to recycle a lot more materials than previously recycled; therefore, non-bottle PET is just another material that we are working towards being able to recycle but have not done so successfully yet.

The reason buyers of PET bottle flake do not want PET/RPET thermoforms is because of the possibility of contamination (one PVC clam could contaminate the whole bale), and the different IV between PET bottle grade and PET thermoform grade, which makes for differences in the way things “fly” and “melt” while being repossessed.

Okay… this seems complicated but not that complicated. I know from previous conversations with Robert that most cities in California accept and recycle plastics 1-7 because of the Integrated Waste Management Act of 1989, which requires local governments to reach a 50% diversion rate. This Act, consequentially, has facilitated the creation of new end markets for these materials post-consumer, which unfortunately, is not the case here.

Do we need to have legislation enacted to provide the motivation to find an end market for mixed rigid plastic containers and packages?

I then received the following email from Robert, which was very much needed in this time of defeat:

Chandler,

Try not to be discouraged. These things take a long time to sort through and creating markets for materials is challenging to say the least! There isn’t just an answer out there waiting to be found. These things need to be teased into existence. They need people (like you) to keep stoking the fire, prodding things along, and creating pressure. Keep at it and you’ll come up with something that’ll work. Maybe it’ll be a few things…at first…small scale. Then maybe one will take off.

The thing about recyclers is that they like what they know (even with Starbucks, they’re facing lots of concerns from recyclers accepting their cups with corrugated). They know PET bottles…so they’re nervous about anything else. Even if it were exactly the same they’d be nervous…so it’d be a matter of either proving through massive testing that it will work the same, or going for another grade of plastic. If you created a new grade of plastic material with its own unique specifications, then everybody would know what to expect from the start. Now…you’d have to have somebody lined up who can use that plastic… It’s a bit of a paradox really…you can’t collect/bale the plastic if there’s nobody to buy/use it, but nobody is going to buy/use it unless there’s a good, steady supply of the stuff with consistent specifications…

Also, PLA will not degrade in the landfill; it requires a commercial composting facility.

Have you considered moving away from single-use thermoformed containers and into more durable containers? Can you make durable containers with the same process? More and more places are feeling the push both from regulators and the public to go green…some are doing it through switching to PLA, some go to cornstarch, and some are going to reusables. Eat-in facilities rather than take-out. Options to fill customer’s dishes with food rather than their own single-use containers. Or even the concept that’s being used with some food manufacturers (deli meats come to mind) where they sell their food product in a container that can be used again and again at home for leftovers…not for refilling its original product…but reused nonetheless.. 

Well, I’ve rambled on long enough! Don’t give up!!! We need people like you in industry!!

Robert

What a guy! Tune in tomorrow for more about recycling in America!

Happy Friday! Spring is just around the corner! I hope everyone has splendid plans for the weekend; if you live in Chicago, you should subscribe to groupon.com, which emails you coupons for the best deals in town everyday! I am cashing in on one of them tonight…

Anyway, let’s resume our clamshell recycling narrative:

Grateful for the educational tour guide’s detailed responses to my inquiries about recycling clamshells, I sent her the following email upon arrival to the office:

Hello,

Thank you so much for your thoughtful reply; I really appreciate it. I am going to investigate the websites you supplied in the email. In the mean time, please feel free to connect me with your plastic rep.

Thank you again for your feedback!

Best,

Chandler

After sending this into the plasma that is the internet, I began going through my inbox, eager to find anything that would continue to provide direction for this clamshell recycling initiative.

The first was from the Sales Director of the SPI, responding to my phone call follow up email:

Chandler,

Sorry to be late in my response. I am working on putting you in touch with the people who can better answer your questions. Unfortunately, between vacations and a benchmarking conference we are sponsoring this week, I am having difficulty getting in touch with those people.

However, we will be in touch with you shortly.

Thanks again for your interest in SPI.

Okay, sounds good. Next I found a response from the APR (Association of Post-consumer Recyclers) in regard to my inquiry about this organization:

Chandler,

Thank you for your interest in plastics recycling and the APR. I have attached a membership application for your review. Please take a look and let me know if you have any questions. I look forward to working with you.

Thanks!

I downloaded and opened the application.

Apparently, depending on your level of engagement with recycling/recycled plastics, different membership categories ensue:

Description of Membership Categories:

• Full Membership—those companies actively engaged – in North America – in performing physical operations of any kind on post-consumer plastics as part of the process of recycling such plastics. (Please see brochure for detailed definition)

• Affiliate Membership—companies that do not qualify for Full Membership and that have a direct business stake in the recycling of post-consumer plastics, except brokers.

Moreover, depending on which kind of membership you apply for, different fees ensure, which is based on your capacity for engaging in the process of recycling post-consumer plastics.

Dordan Mfg. has a closed loop system with its material supplier in which we grind our scrap post-industrial and sell it back to our suppliers to be formed into sheets for future conversion. Therefore, while we do engage in a process of recycling (collecting and grinding our post-industrial scrap), I don’t believe we can qualify for full membership because it specifies post-consumer, as opposed to post-industrial, recycling processes.

Hmmmm…I don’t know if this pertains to us exactly….And, there are annual membership fees…perhaps I can persuade my Superior to consider this?

…ten minutes later…

As in the case with joining NAPCOR, my boss doesn’t see the economic justification for joining the APR at this point in time: the economy is bizarre and he already brought me on as the Sustainability Coordinator; my role, he explained and continues to emphasize, is to understand sustainability from the role of a packaging professional in order to further the success of Dordan and implement logistical, economically viable initiatives: “Don’t let your passions get in the way,” he said to me. Again, another realization that this was not a school project but a profession that only exists as long as it is economically sustainable.

So, now that I have researched the various recycling trade groups but am unable to apply for membership, there has to be more things I can do to further this clamshell recycling initiative…

Luckily, I received an email from the educational tourguide at Recycle America, a division of Waste Management, following through with her offer to put me in touch with some people that may be able to help forward my clamshell recycling initiative:

Chandler,

You should be seeing two emails with you copied on them as an introductory.? One will be to our plastic rep and the other will be to one of our municipality reps.

The educational tourguide copied me on the following emails:

Hello,

Chandler Slavin is inquiring about the market challenges of clamshell containers among other things. As a Sustainable Coordinator for his company and a member of the IoPP (Institute of Packaging Professionals), she wants direction on how to go about researching best practice collections for the packaging his company creates. Could you spare a few minutes to answer some more specific marketing questions?

And:

Hello,

Chandler Slavin is inquiring about the recycling challenges of clamshell containers among other things. As a Sustainable Coordinator for her company and a member of the IoPP (Institute of Packaging Professionals), she wants direction on how to go about researching best practice collections for the packaging his company creates and asked if she should look into questioning the municipalities as a part of this research. Could you spare a few minutes to answer some more specific municipality questions?

Thanks!

Groooooooovy. Tune in on Monday to learn more about the intricacies of recycling and waste management in America.

I just spoke with my contact at Recycle America, a division of Waste Management. She is excited about what I am doing and wants to help; she just wants to make sure that I contextualize our conversations so things are not misinterpreted going forward.

Let me provide a quick summary of the role Recycle America/Waste Management has in recycling plastic packaging:

Waste Management collects materials to be recycled via curbside collection and community drop-off centers. This is a single stream system, which means that the individual must still separate it from garbage, but can now place papers, glass, metals and plastics together in ONE collection bin.? Once collected from the curb, the materials are brought to a recycling facility where they are further sorted: HDPE milk jugs are removed and bailed, cardboard, PET bottles and any other material that has a “home” are removed from the stream and designated to their specific bailing location. A home means that there is an end market for it. In other words, if there is not a buyer of this post-consumer material, then Waste Management can’t economically validate the separation and bailing of said material, which unfortunately is out of their control. As the educational tour guide explained to me, they want to find a home for every material; however, if the market is not there and there is no buyer, there is nothing they can do because the cost to bail and warehouse the homeless material exceeds the operational costs of the facility at this time.

So, while Recycle America accepts a lot of different materials for recycling, if there is no buyer, the material must be land filled. This ebbs and flows with the changing marketplace, however. The educational tour guide explains this relationship as follows: Recycle America is the distributor of post-consumer materials. They have contracts with different brokers who buy the bailed material and convert it into another usable product. Reclaimed plastic material gets sent to a plastic house, where it is cleaned and turned into flake or pellets to be sold to packaging material suppliers; reclaimed paper material gets sent to a paper mill, where they retrieve the fiber content and reprocess it into recycled paper products.

In a nut shell: Recycle America collects, sorts and bails materials post-consumer that have a home or an end-of-life buyer, like a plastic material supplier or paper mill. While Recycle America tries to find a home for every material, depending on the marketplace, some materials must be land filled. This too, however, must be put into context with the changing marketplace and the economics of supply and demand.

Now that we have contextualized the role Waste Management plays in recycling, let us turn to the email I received from the educational tourguide of Recycle America, which helps explain the complexities of recycling:

Chandler,

I very much appreciate your patience and so sorry that you had to check in again before I could respond (yikes - don't ever tell me to take my time . . . it always gets away from me!!)

I also wanted to thank you for the kind words. I do try to be as honest as possible (without being confusing) as I believe it is the only way we can all work towards the most efficient and effective recycling efforts.

I will answer these questions as best I can.

As you explained, you would like to find a home for every kind of material; however, that is not always the case because a material’s ability to be recycled is often determined by the quantity of material available in the waste stream. Watching the live feed video yesterday, I was startled to observe that no clamshells, blisters, or plastic packaging of any kind was making its way through your sorting system. Why is that? Is there just not that much plastic packaging out there, (which I find unbelievable), or, are these materials being sent somewhere else or just thrown in the garbage? If sent somewhere else, where? And if just thrown into the garbage, why?

Very good questions. I'll try to break this down based on what I know at this time.

a) Materials, like clamshells are changing. Originally, many were #6 PS - now many are PET . . . (very hard to tell on our lines first) and as I understand it - it's a recycled PET . . . our buyers are very specific in what they want IN these bales - bottle-form only. WHY ???? I imagine it has to do with how these other containers process in the melting stage . . . I am no scientist but my plastic Rep can best answer this.

b) As for the volume issue - this is one of our biggest challenges with specific materials for our TYPE of facility. Many things can get recycled but in a sorting facility like this one - VOLUME is key. What might appear to the general public as a lot - is really not when you take a look at our tipping floor. The open markets who buy our bales set the specs on what they want IN the bale (this is out of our hands). If they do not want a certain material - like a lot of those clamshells, we would have to pull those. If we are to find the soundest markets, it depends on gathering enough of a particular material to make a specific bale - then we need to make several bales to make a truck-load. This is where it boils down to pure volume challenges.We cannot just collect something for a while until we have enough of it. That is why redirecting certain materials to smaller markets works good sometimes - but the CONSUMER has to do this part. Future hope is to have enough of ANY material to make it's OWN bale . . . all things take time and in the heart of the growing pains, there will be some casualties - while we (remember - just the middle sorting man) CONTINUE to work towards best-practices. This is where the consumer can becomes more savvy and assist in finding a better home for it temporarily but what you will find is that many will not have the time to put towards this special attention- so we would rather they error on recycling with these things and let us figure it out. A general 1-5 plastic is stated and we output as the market allows. We have to be general with the public in literature as it would confuse too many things as these markets continue to ebb and flow. But YOU, the packaging side needs to understand what the current challenges are and spec accordingly - make sense?

c) As far as these materials being sent somewhere else rather than coming in here - some unfortunately end up in a landfill simply because people will throw them in garbage. Others will be mindful to check local markets for collectors of this stuff and others are simply making sure they are not using these containers - I cannot know for sure where all these are going.

d) If I want to attain my goal of being able to implement a recycling program for non-beverage PET flake in this region, where do you suggest I start? Should I begin a dialogue with all the plastic packagers in the region to find a way to reclaim our packages in order to divert them from ending up in a landfill? Should I begin with the local municipalities? Or with the waste management facilities?

YES . . . to ALL the above. But I think you need to start from the outside and work your way up as a means of collecting facts about the challenging markets. Start with our plastic marketing rep (I will provide an introductory email for you). Pull off some of the local community / municipality guides and see whose collecting and marketing these in the area. Check out sites like: www.earth911.org , www.freecycle.com and see what those places are suggesting to their communities. And YES, most importantly, take the gathered information of limited available markets and sit with your plastics packagers and CREATE an END MARKET and convenient collection options for these harder to place materials. The creator of the package should step up to assisting in finding or creating markets for these materials.

e) How do you feel about incineration as a form of waste management?

It's one of a few great ways to manage solid waste. We have our own called Wheelabrator. They are incredible waste to energy facilities - but there are only 21 sites so far as the cost to build one has to be justified. The filtration system alone is incredible - the air that comes out of those facilities is probably cleaner than what you and I breath now- they're heavily monitored - check them out on our educational site: www.thinkgreen.com.

Again - a great way to MANAGE waste.

f) Today in the packaging world, there is a lot of marketing that positions one packaging material as more “environmentally friendly” than another; often this debate places paper in opposition to plastic. After performing several months of research on this debate, I have discovered that while plastic comes from oil (which is obviously not a renewable resource) and requires more energy to create than paper, it doesn’t release as many VOC and greenhouse gases into the atmosphere as does the paper and pulp mills in the US. Therefore, it is a trade off and packaging material should be selected on a case-by-case basis depending on the application of the package. I was just wondering, where do you stand in the paper versus plastic debate? How can plastic packaging become more sustainable?

Yeah, I was getting ready to duck when that little debate started to air.Please know that I respect individual passion pleas - I think the world needs to have passions in order to spur good works, it's just passions need perspective in place or it usually ends up becoming ineffective. I represent WMRA . . . and I also have my personal thoughts but in this "debate", I believe my company would agree with what I am about to share. I (we) cannot take sides. NOT because I am not more passionate on one side or another . . . but rather because we all have to keep PERSPECTIVE. There's an argument for anything in life. If I'm preaching about learning to spend energy better by making certain choices like recycling that spend energy smarter- I won't waste my personal energy trying to ARGUE these points - you know?

Here's the deal - NO package is perfect. Nature - natural resources in and of themselves are perfect but the minute we start changing things and creating new things out of them, we alter how they will break down - period. Any packaging has pros and cons to it's production. Sadly alot of packaging should probably have never been created. Old way of doing things never had this much packaging. REDUCE is the first part of the recycling structure yet no one pays attention to it. So, now that we are HERE, we have to work together to MANAGE what is on the market. We have to work together to create effective recovery plans for EACH package. And when packaging cannot be recovered - it needs to go away. Sadly, we cannot simply just make one system disappear as it would cause negative overload in another area: ONLY paper package would greatly deplete forestry - only plastic packaging would greatly impact petroleum . . . again just my take on things.

Okay, that is a lot of questions. I would love the chance to speak to you about this in person or over the phone. When is a good time to reach you?

I can make myself available for a conversation but it will probably not be until next week - sorry - just packed full of tours. Let me know if you have time next week and I will try to coordinate time.

If there is anything I can do for you—be it supply you with some of the research I have compiled on the sustainability of packaging materials, or speak to students about our sustainability efforts in the plastic packaging industry, please let me know.

I would love to take you up on this and will chat about this in detail when we speak.? Thank you for making yourself available - I not only enjoy learning more personally?but find it necessary to be able to communicate effectively in these discussions.

Again, it was a pleasure to meet you and I look forward to speaking with you again!

P.S. Could you please provide the contact information of your “plastic marketing guy?” Moreover, is there someone in your organization that could provide me with the contact information of someone in the local municipalities?

I will send you introductory email on both our contacts.? Hope this all makes sense.

Wow. That is a lot of really good information. Another bread crumb? I’d say several!

Tune in tomorrow to see where this information takes me!

The next day I arrived to the office full of enthusiasm; I had brought my favorite lunch—penne puntanesca and garlic bread—which ensured that no one in the office would want to talk to me for the duration of the afternoon. Silence is golden. ;)

After establishing that NAPCOR was super cool but a little outside our means at this time, I found another industry group dedicated to the use and recycling of plastics: APR stands for the Association of Postconsumer Plastics Recyclers. Like NAPCOR, they represent those in the industry that work with post consumer plastics. Their website reads:

Our goal is simple-we want to increase the amount of plastic material that is recycled in North America. We do that by sponsoring education workshops and ‘webinars’ designed to help local and state solid waste officials learn more about the technology of plastics recycling and the markets for material; holding design for recyclability workshops for packaging professionals; working to assist legislators to make decisions that enhance the recycling of plastics; and numerous other market development and technical programs.

RADICAL… I sent a letter of inquiry to the email provided:

Hello,

My name is Chandler Slavin—I am the Sustainability Coordinator at Dordan Manufacturing, which is a Midwestern based, national supplier of custom thermoformed solutions. We source post consumer RPET for manufacturing our packages and are currently investigating recycling options for the end-of-life management of our products. After visiting your web-site I am interested in your association and would like to know the process of applying for membership and also the advantages of being a member. Are any thermoform members in the APR?

Thank you for your time and I look forward to speaking with you soon!

Best,

Chandler Slavin

In a previous post I described a conversation I had with a representative from the SPI (plastics industry trade association); I discussed her desire to help increase the recycling rates of plastic packaging but emphasized her underlining understanding of economics and how such economics did not support such an initiative. During this conversation I suggested that the SPI revisit the resin ID numbers currently prescribed to different polymers used in plastic packaging in order to account for the introduction of PLA into the stream and make recycling of plastics easier. She subsequently indicated that a subcommittee was formed that year to address these concerns and indicated that she would follow up with me about their approach.

To my surprised, that day I received a follow-up email from this contact:

Hi Chandler,

Thanks so much for the call earlier and the great conversation. Sounds like you have your hands full with issues surrounding sustainability, “green-washing”, recycling, bio-resins, additives, resin identification code, Wal-mart Scorecard, and the ultimate goal of reclaiming all your clamshell packaging. These issues are being addressed in our processors council and materials supplier council predominantly.

I have touched base with our sales director in the Midwest. He will follow up with you to give you a better sense of the issues, including the above, that we are involved with on behalf of industry. And, certainly I am available as well.

Hurray; another bread crumb! Processors council and materials supplier council, eh? Time to do more research!

After lunch that day, I got a call from the Midwestern sales director of the SPI. He was really cool, and although he wasn’t totally versed in sustainability issues, he listened to what I had to say and told me he would put me in touch with someone at SPI that would be more of a help to me and my inquiries.

Splendid.

Ironically, later that day, just as I was assembling my things to catch the train back to Chicago, I received the following email:

Dear Plastics Industry Professional,

On September 23, 2009, ASTM International's D20.95 subcommittee on Recycled Plastics distributed a new draft subcommittee ballot on the resin identification codes to its membership. There are 18 new items being balloted as part of the draft, which will update the original system developed in 1988 by SPI. Members of the D20.95 subcommittee are eligible to vote on the draft until its closing date on October 23, 2009. SPI is strongly encouraging all members of D20.95 to review and vote on this ballot.

Huh…so the SPI is reconsidering the resin ID numbers; that’s great! Although the language of this email is a little ambiguous, at least they are being proactive about these issues. I wonder how I get involved…

Just before I walked out the door, I sent the sales director of the SPI this follow-up email:

Hey,?

?I just wanted to send you a quick email to follow up with our phone conversation today. First, thank you for taking the time to talk with me about my concerns regarding the plastic packaging industry. As per our conversation, I was wondering if there were any contacts at your association who would like to have a dialogue with me about issues pertaining to sustainability and the plastic packaging industry. Aside from the millennial campaign and discussions about adding to the SPI resin identification number family, what else is SPI doing to confront the challenges facing our industry? How is SPI working to save the reputation of the plastic industry? What kind of initiatives is SPI taking to increase the sustainability profile of plastics? Is SPI considering different material recovery technologies or recycling programs?

As per our conversation, I have spent a considerable amount of time researching issues pertaining to plastic and sustainability. If there is anyone I could talk with, or would appreciate talking to me at SPI or one of its sister organizations, please let me know. ?

Thanks!

Chandler

Tune in tomorrow for more recycling in America tidbits; good times!

And resume scene:

As I waited for Recycle America’s educational tour guide’s response to my inquiries, I followed up with Robert about Polyflow. As you will recall, I sent Robert an email asking if he knew about Polyflow and if so, what he thought of this form of waste management.

This is what I learned:

Chandler,

What Polyflow is describing is called Pyrolysis and the technology is not unique to this company. I’m not sure about the “vapor” part though…There are discussions regarding this method in CA and elsewhere.? In CA, we don’t use energy recovery as a part of recycling (or diversion) so the portion of the pyrolysis that results in diesel or other fuels would not be counted in our recycling numbers. Also, some people are afraid that if the “easy” option is presented (the same goes for incineration) then recycling for higher and better uses will have no appeal. Using plastics for energy is seen as a lower use than using it for a new product. For some plastics, there are not other mechanical recycling options available, but the fear is that this kind of thing would prevent new technologies being developed, that people would stop trying to find better options if the easy option is available.

Further, the analyses I’ve seen on the environmental/energetic impacts of mechanical recycling versus pyrolysis puts mechanical ahead of the game pretty much under every circumstance (assuming there is infrastructure). 

I don’t mean to shatter your hopes…it’s a good technology, and would be appropriate for a few materials that have no other options (in my personal opinion), however I think there would be challenges to implementing it wholesale (at least in CA…perhaps Il is different).

I’m surprised that the Sustainability Director of Starbucks hasn’t contacted you, he seemed interested in speaking. I wonder if perhaps your email simply got buried. Have you tried sending him the email again? I’ve looked around here and I’m not sure that we really have a person on the local level that would be particularly suited. I suppose I’m it…sorry!!

Robert

Hmmmmmm using plastics for energy is seen as a lower use than using it for a new product? That’s interesting; I didn’t know there was a hierarchy to waste management. If most plastic packaging ends up in a land fill, wouldn’t a better option be waste-to-energy? If easier, why not utilize the technology until the recycling infrastructure catches up? I wonder why CA doesn’t count this form of recovery into their recycling numbers. This seems sort of odd…

As I tried to sort through the implications of Robert’s response, I received an email from the Sustainability Director at Starbucks, yippee! He agreed to chat with me about implementing a pilot-recycling program in several NY Starbucks stores.

Little old me, I remember thinking. This is big time!

The actual email has not been included for privacy considerations.

Upon setting up a phone interview with the Sustainability Coordinator of Starbucks, I sent the following email to Robert:

Hey Robert,

Thanks for your feedback. I feel so silly; the rep from Polyflow didn’t even mention Pyrolysis, which I know about and know is not unique to this company. Thanks for clarification!

As it turns out,?the Sustainability Director of Starbucks?is available to talk with me, and my email did get lost in the plasma that is the internet, so thank you! I also have been engaging in dialogue with various people in Waste Management trying to figure out a way to recapture PET clamshells and what not, so I feel as though I am on the right track.

So until next time, take care and thanks again for all your help; I really appreciate it!

What are you doing for Halloween? I dressed up as a man for our office party and just got done handing out candy to everyone in the plant. It is fun to be a man for a day!

Chandler

Tune in tomorrow to learn more about recycling in America.

Cheers!

Happy Monday Funday!

I hope everyone enjoyed the Superbowl. What was your favorite commercial?

I swear, my job as the Sustainability Coordinator at a plastic company is making me crazyyyyyy! I interpret any reference to the environment and plastics in the context of popular culture as a case to be studied; as an academic text to be analyzed.

Such crazyiness manifests itself in my life outside work, when, for instance, I am watching the Super Bowl with friends, drinking beer and eating pizza.

And roll Audi commercial about the Eco-police:

Opening scene: Would you like paper or plastic?

My ears perk up; my senses ready.

Plastic, the man at the check-out counter says.

Enter: Eco Police. They arrest the man at the counter, thereby implying that because he opted for plastic, he is transgressing against our ecosystem. Ug!

And the funny thing is, Obama suggested that American-produced cars utilize more plastic in their construction than previously manufactured cars because it makes them lighter; therefore, less energy consumptive.??

AND the new Audi has plastic components for this very reason. It’s cool though—I understand what the marketers of this car were going for; after all, this Audi runs on diesel, which releases less green house gases than the burning of fossil fuel. So that’s neat. I just wish they wouldn’t continue to propagate the notion that plastic is bad for the environment when, because of its lightweight and versatile properties, it actually facilitates innovation in the field of sustainability.

You can check out this commercial at: http://www.youtube.com/watch?v=O_MuqoSsuTQ&feature=player_embedded.

Anyway where am I? Oh that’s right; awaiting an email from the educational tour guide from Recycle America…

Until I speak with this contact about the contents of this email and receive her approval to include it in this blog, I am unable to continue the narrative at this point. Sorry for the inconvenience.

Hello and sorry I did not post yesterday! I am actually going to postpone blogging until I have gotten the necessary approval from those I include or intend to include in my blog. I recently realized that some may be uncomfortable with me sharing our conversations via email on my blog; in order to ensure that my relationships with these people are not compromised, I am waiting on their approval before I continue. Sorry for the intermission. I will resume with my recycling initiative narrative ASAP.

Tootles!

Happy Friday!

I finally figured out how to add tags to my posts, hurray!

After tagging it up, I tried searching one of my tags in the wordpress.com search engine. I started with “clamshells” and what I found was all sorts of crazy stuff. My favorite is “Death to the Clamshell” at: http://envirogy.wordpress.com/2009/08/25/death-to-the-clamshell/. Check out my reply, it’s the last one.

Anyway, while waiting for the educational tour guide’s response, I began researching incineration as a form of energy recovery for plastic packaging. As briefly discussed in my last post, Belgium is at a 96% packaging waste recovery rate because of their sophisticated recycling and incineration infrastructure. That which they can’t recycle, they incinerate. Why don’t we do that here, I wondered.

After several googling sessions, I stumbled upon this “new” technology called Polyflow. I called the number provided on the website…

After a quick Q&A with their rep, I was a little skeptical about this technology because it just sounded too good to be true. Because I didn’t know much about it, I sent Robert the following inquiry:

Hey Robert,

How’s it going? I saw Where the Wild Things Are this past weekend and it was AWSOME! You must see it at your earliest convenience.

Okay, I don’t want to be a nuisance, but have you heard of Polyflow? It is this new technology that breaks the plastic polymer chain down into its chemical components by vapor and then reconstructs the molecules in order to create diesel and fossil fuel and the monomers that make plastic polymers. This technology supposedly takes all types of plastics not currently recycled by single stream and provides the feedstock for the above mentioned products. I spoke with a representative from Polyflow and he says that this system will be economically and environmentally sustainable next year but that they are still in the pilot phase and need additional funding to construct the actual facility that will house this technology.

Any knowledge about this waste management alternative?

Moreover, I have not heard back from the Environmental Director of Starbucks and was wondering if you had unearthed any contacts at your organization that would be able to help me implement my recycling program. I have a dialogue going with SPI, our industry association, but they don’t think the economics will support it.

Hope all is well!

Best,

Chandler

My reference to SPI, the Society of Plastics Industry, was legitimate; I had spoken with one of their reps about my concerns about the environmental and plastic, specifically, recycling, and it went no where.

I first spoke with the Senior Director of State Affairs, who does a lot of petitioning for plastic on our industry’s behalf. She was aware of all the obstacles facing our industry but didn’t seem interested in helping me increase the recycling rates of plastic packaging because, as she explained, it is just not economical: If people can buy virgin resin for cheaper than recycled resin why would we work to create an end-of-life market for mixed rigid plastic packaging?

My one suggestion was to change the SPI resin ID numbers on the back of plastic packages. For instance, the number “1” indicates PET but doesn’t specify the various fillers added to the PET polymer to enhance/alter its properties. Therefore, we manufacture APET, RPET, RPETG, PETG, etc. and they are all labeled as “1” as mandated by the SPI. Because of the different additives in these polymers, the recycling facility won’t accept any thermoforms labeled “1” because they do not know how that specific additive will influence the overall integrity of the bale. Therefore, although it may be the same material as that in PET bottles, they can’t integrate it into the bales to be reprocessed for fear of contamination.

As an aside, PLA is just making its introduction into the market and I don’t know if it has been assigned a resin ID number; therefore, sorters may not be able to distinguish PLA bottles from PET bottles, thereby increasing the chances that the PET stream will be contaminated by PLA. I don’t know what the PLA people have to say about it…I will follow up with some more research in future posts.

Do check out this article; it may provide insight into the ramifications of incorporating into the PET recycling stream: http://www.linkedin.com/news?viewArticle=&articleID=107200234&gid=160429&srchCat=RCNT&articleURL=http%3A%2F%2Fblogpackaging%2Eblogspot%2Ecom%2F2010%2F02%2Fbioplastics-and-oxo-degradables%2Ehtml&urlhash=oSuc.

Anyway, I suggested that SPI be proactive and work with recyclers to develop the best labeling for resins to increase the recyclability of plastic packaging.?Although this contact did not know?exactly how?the SPI was handling the resin ID number situation, she did say that they had a?subcommittee devoted to the investigation of these issues and she would follow up with me about this subcommittee...??

Tune in Monday to see Robert’s response to my Polyflow inquiry. Good stuff to come; have a splendid weekend!

The next day I received the following email from the educational tour guide at Recycle America:

Chandler,

I just received this and will gladly answer as best I can but it will not be until tomorrow as I have tours.I appreciate your patience.

Lisa

Okay…what else can I do in the meantime to move this initiative forward?

I thought back to the lectures at the SPC’s members-only meeting in Atlanta. The president of Environmental Packaging International (hereafter, EPI) gave a very honest presentation about environmental marketing. Basically he explained what kinds of environmental claims on packaging are misleading or manipulative and what kinds are acceptable. Because the FTC is being restructured, he explained, they have not been able to investigate the environmental claims on packaging; however, that will change, and those making unsubstantiated or vague claims will be sought out by the FTC. Therefore, he explained, it is in all of our interest to only make claims that can be validated via scientific analysis.??

Hurray, I remember thinking. Finally, marketers will be held accountable for manipulating consumer’s desires to do well by the environment.

To be honest, I probably would not have a job at Dordan as the Sustainability Coordinator if people in our industry were not greenwashing. In other words, it was because my father, the CEO of Dordan, didn’t know how to interpret the claims being made by our competitors that he hired me to investigate them. And what I found, more often than not, was because the FTC didn’t have the man power to investigate environmental claims our industry was in sort of a Wild West limbo where marketers could get away with saying almost anything. This Wild West limbo was catalyzed by the recent consumer research that showed how most consumers would buy the product with the better environmental profile if at a comparable cost and performance to other, less environmentally friendly products. I am sure we are all familiar with this…

Anyway, I remember the President of the EPI discussing the Mobius Loop symbol and how that can be a form of greenwashing in and of itself insofar as it implies recyclability or recycled content. All of our packages have this symbol, which houses the SPI resin identification number; both the symbol and ID number were mandated by SPI (Society of Plastics Industry) decades ago.

I sent the President the following email, hoping to get some clarification about the applicability of this symbol to our packages:

Hello,

This is Chandler Slavin with Dordan Manufacturing—we spoke briefly following your presentation in Atlanta entitled, “Are the Labeling and Green Claims on Your Packaging Meeting FTC and Retailer Requirements?” First, I wanted to take this opportunity to express my gratitude for your presentation: it was the most honest, direct, and educationally insightful discussion I had yet experienced at the forum. At the same time, however, there are some questions still lingering.

For instance, you said that the mobius loop i.e. chasing arrows symbol, which houses the SPI resin identification number, implies to the consumer that the package is either: (1) made out of 100% recycled material or, (2) is 100% recyclable. After telling this to the president of our company, we were confused because we thought that this symbol was mandated by the SPI. Are you and the FTC suggesting we remove this symbol from our packages? Is there someone at the FTC we could talk with for clarification? Is there someone at SPI that would be of assistance?

Sorry for the quick-fired questions: this is all new to us and we are trying to be honest with our labeling in order to inform our customers about the sustainability of our packages. Additionally, I would really like the opportunity to talk to you about industry-led EPR initiatives in the U.S. When would be a good time to reach you?

Best,

Chandler Slavin

The same day, I received the following email from the President of the EPI:

Chandler,

The SPI code as required by 39 State Laws are allowed if used as prescribed by those laws. If you placed it in an inconspicuous location on the container (e.g., embedded in the bottom of the container) it would not constitute a claim of recyclability or recycled content and is allowed.

If you have a questions let me know, Hope this helps.

Phew…I thought to myself; we only place the chasing arrows symbol on the bottom of our packages. We are FTC clear, at least for now.

Tune in tomorrow for more recycling in America tantalizing tid bits.

Sorry I didn’t post yesterday! I was on a deadline to finish a condensed version of my research on sustainability and packaging titled, The Facts.

Okay, back to the story:

The day after I received the “ok” from Robert, I sent the Environmental Director of Starbucks the following email:

Hello,

My name is Chandler Slavin—I am the Sustainability Coordinator at Dordan Manufacturing, a Midwestern based custom thermoformer. I was given your information from Robert Carlson with the California Integrated Waste Management Board, whom I met in Atlanta at the SPC members-only fall meeting. I believe I also met you (sort of) in one of the break out seminars on “Closing the Loop” (where you the one who asked how Starbucks cups could be integrated into the existing recycling infrastructure?)

Anyway, Robert said you may be of assistance because you were involved with implementing the pilot recycling program in several New York Starbucks stores and I am trying to implement a pilot recycling program in the Midwest for reclaiming thermoform PET clamshells, blisters and components. I have so many questions for you I don’t know where to start: Are the Starbucks cups compatible with the existing recycling infrastructure i.e. can they be recycled with other paper/cardboard products or do they need to be sorted? If sorted, by whom and where? Did you begin with the municipalities and the local MRFS to determine what can be recycled in your region and what is needed to allow a new product into the recycling stream? Where is the funding for this program coming from?

Yikes! The list could go on and on. Would it be possible to speak with you about your sustainability efforts at Starbucks over the phone? I would love to set up a phone interview with you at your earliest convenience. Please let me know when and where I can reach you.

Thank you so much for your time and I look forward to speaking with you soon!

Best,

Chandler

After sending, I automatically received an “out of the office” reply. Rats!

Luckily I scheduled a fieldtrip to the Recycle America Waste Management Facility in Grayslake with the Institute of Packaging Professionals. It was the first time I got to see a modern MRF in action!

The Dordan Sales Force and I set out on our journey to Grayslake; the wind was in our hair, the pastoral scenery was all around, and Tony’s Famous Subs were in sight. After a scrumptious filling of salami and ham, we made it to the recycling facility.

The two hours we spent at the Grayslake facility were jammed packed: we had a tour of the facility, got to watch live footage of the process of recycling, and had a Q&A session. During the Q&A session, my fears were confirmed: Most plastic clamshells do not get recycled at this current time, even if they make it to the material recovery facility. Ug!

While Waste Management says that it accepts plastics 1-7 for recycling and tries to find an end-market for these materials, only PET beverage bottles are currently being processed at this facility because of the current market demands; this changes with the ebbs and flow of the market, however. Our educational tour guide did explain that this is because the buyers of the PET bales specify that they do not want any thermoforms in the bale, even if it is the same material type.

As an aside, on the East and West coasts, mixed rigid plastic packaging is collected and recycled because of the different markets available and the overseas demand.

The day after our field trip, I sent the following email to our educational tourguide:

Hello,

This is Chandler Slavin—we met yesterday at the Recycle America Waste Management facility in Grayslake. I was with the Institute of Packaging Professionals and I kept asking about how we could create a recycle stream for non-beverage PET flake i.e. clamshells, blisters and trays.

I just wanted to drop you a quick email thanking you for allowing us to visit the facility and for presenting such an honest discussion of waste management and recycling in this region.

Being a representative from the plastic packaging industry, I was wondering if I could pick your brain in regard to the following:

1. As you explained, you would like to find a home for every kind of material; however, that is not always the case because a material’s ability to be recycled is often determined by the quantity of material available in the waste stream. Watching the live feed video yesterday, I was startled to observe that no clamshells, blisters, or plastic packaging of any kind was making its way through your sorting system. Why is that? Is there just not that much plastic packaging out there, (which I find unbelievable), or, are these materials being sent somewhere else or just thrown in the garbage? If sent somewhere else, where? And if just thrown into the garbage, why?
2. If I want to attain my goal of being able to implement a recycling program for non-beverage PET flake in this region, where do you suggest I start? Should I begin a dialogue with all the plastic packagers in the region to find a way to reclaim our packages in order to divert them from ending up in a landfill? Should I begin with the local municipalities? Or with the waste management facilities?
3. How do you feel about incineration as a form of waste management?
4. Today in the packaging world, there is a lot of marketing that positions one packaging material as more “environmentally friendly” than another; often this debate places paper in opposition to plastic. After performing several months of research on this debate, I have discovered that while plastic comes from oil (which is obviously not a renewable resource) and requires more energy to create than paper, it doesn’t release as many VOC and greenhouse gases into the atmosphere as does the paper and pulp mills in the US. Therefore, it is a trade off and packaging material should be selected on a case-by-case basis depending on the application of the package. I was just wondering, where do you stand in the paper versus plastic debate? How can plastic packaging become more sustainable?