Blog

Another sunny day in Chicago! I just don’t know what to do with myself!

The next day I arrived to find an empty inbox. Ug! I had sent out a gizzillion emails and gone as far as I could go with my recycling initiative until I knew the status of our “test.” Four weeks all of a sudden felt like a life time…

I scrolled through my emails to see if there was anything I had forgotten to follow up on. And then it hit me: my phone-interview with the Environmental Director of Starbucks about the launch of his cup-recycling program. Below is the editorial about this initiative, which got me interested in talking with the Environmental Director responsible for its implementation:

NY Starbucks stores launch cup-recycling program

Posted by Anne Marie Mohan, Managing Editor, GreenerPackage.com, September 10, 2009 

Seven Starbucks stores in Manhattan have launched a cup-recycling program in cooperation with Global Green USA’s Coalition for Resource Recovery (CORR). The pilot will test the collection and recycling of coffee cups when combined with old corrugated cardboard (OCC), which CORR says is the most extensively recycled material in the U.S. The objective of the program is to develop a cost-effective mechanism to close the loop on paper packaging, reducing greenhouse gases and assisting municipalities in reaching their solid waste diversion goals.

Starbucks participation in the pilot is an extension of the company’s efforts to develop a comprehensive recyclable cup solution by 2012. While Starbucks paper coffee cups can be recycled and composted in some communities, most commercial and residential services are not currently able to process this form of packaging. “In addition to the cup design, it’s critical that we address the full product life cycle—including the recycling collection infrastructure,” says Jim Hanna, Starbucks director of Environmental Impact. “Any enduring solution will require collaboration with stakeholders across the value chain.”

For the pilot, Western Michigan University’s Coating and Recycling Pilot plants tested a representative sample of the cups used in Starbucks stores and certified them as OCC-E, offering equivalent recyclability and repulpability as old corrugated cardboard using the Fibre Box Association's Wax Alternative Protocol.

Paper bag manufacturer Duro Bag is designing a special paper bin liner so cups can be collected and recycled along with the corrugated cardboard. The prototype bag will be tested as part of the trial. Action Carting, the largest commercial carter in New York City, is collecting the bags along with the corrugated cardboard.

Pratt Industries will recycle a trial run of the bags and their contents, testing them for their recyclability and repulpability compared to existing feedstock at the company’s mill on Staten Island. Pratt’s Sustainable Design Incubator provided design guidance for the pilot, which is being coordinated and monitored by Global Green USA. Results of the pilot will be available in November.

According to CoRR, every year, 58 billion paper cups are used in the U.S. at restaurants, events, and homes. If all paper cups in the U.S. were recycled, 645,000 tons of waste would be diverted from landfills each year, reducing greenhouse gas emissions by 2.5 million mtCO2e, equivalent to removing 450,000 passenger cars from the road.

Says CORR director Annie White, “The lessons learned from the cup recycling pilot can be applied to the recycling of hamburger, pizza, and French fry containers, and all sorts of other paper food packaging. If the initial pilot is successful, CORR will expand the pilot to encompass more packaging types and restaurants, furthering our objective of generating business value and closing the loop on packaging.”

According to James McDonald, director of Sustainability for International Paper, “As an active member of CORR, International Paper supplied cups to Western Michigan University for recyclability testing and subsequent approval to the OCC-E protocol. Our participation not only supports this important pilot, it also furthers International Paper's goals of providing responsible sustainable packaging for our customers.”

The foodservice packaging recycling project is but one of several of Global Green USA’s CORR projects dedicated to generating business value through creating a sustainable, zero waste New York City. In March, CORR launched an initiative with the Hunts Point Distribution Center in New York City, the world’s largest food DC, to substitute all of its nonrecyclable transfer packaging with recyclable packaging.

To visit this article on greenerpackage.com:

http://www.greenerpackage.com/sourcing_renewable/ny_starbucks_stores_launch_cup-recycling_program

Robert Carlson with the CA EPA had suggested I contact the Environmental Director of Starbucks after I had introduced my recycling initiative that looks to find an end-of-life market for thermoformed packages post-consumer to him. I was honored when the Environmental Director agreed to talk with me in October. I had not yet been able to get my interview, even though I was just as determined.

I sent the Environmental Director of Starbucks the following “reminder” email:

Greetings,

Sorry to be a bother but I just wanted to reaffirm my interest in chatting with you about the status of the pilot recycling intiative for Starbucks coffee cups in several NY Starbucks’ stores. I am trying to find an end of life market for our RPET plastic packaging (clamshells, blisters, trays, etc. [non-food]) either within the existing PET bottle recycling infastrucitre or by creating a new end market for mixed rigid plastic packaging. It seems as though buyers of baled PET don’t want plastic packages in it for fear of PVC contamination or the introduction of other contaminates. I was curious how buyers of baled corrugate were handling the introduction of a new material (Starbucks coffee cups) because I feel as though it is a similar situation with persuading buyers of baled PET that RPET clamshells will not contaminate the feedstock.

Please let me know when I can catch you in the office.

Thanks!

Chandler

Tune in tomorrow for Robert Carlson’s (with the CA EPA) response to the “what’s new with me” email. It is jam-packed with goodness!

On November 16^th I received the following email from my contact at Waste Management, confirming receipt of our RPET samples:

Chandler,

I received the samples to run through our optical sorting technology. I will send them out for analysis and be back in touch in a few weeks.

Grooooovy. A few weeks…yikes! The suspense is already killing me!

While I contemplated waiting for “a few weeks” to continue moving forward with our recycling initiative, I sent Robert the following email, inquiring into his opinion about PVC, a thermoplastic that we form.

Hey Robert,

What is your stance on PVC? I know that that is a loaded question, but I run into contradictory information all the time. For instance, below is an article on Dr. Patrick Moore, a Co-founder of Greenpeace, who left the organization because it’s increasingly radical stance on chlorine in all its forms and derivatives. He says that PVC is a good material in specific applications and I can infer that the language on greenpeace.com (“PVC is a poison throughout its entire lifecycle”) is extremely reductionistic. What is your stance on greenpeace? Do you have any contacts there who may be able to provide insight into their harsh stance on PVC, and plastics in general. Moreover, a lot of their experts specialize in the protection of forests from the pulp and paper industries around the world; would they have information on the timber industry that may provide a counter-argument to language like “dino plastic” used by bloggers on greenpeace.com?

Gosh, I know you’re busy. Please take your time and respond at your earliest convenience. Perhaps we should establish a question quota per week? Ha!

See the article and link below for more info.

Best,

Chandler

Greenpeace Co-founder Praises Benefits of Vinyl Products in New Video

Dr. Patrick Moore, the co-founder and former leader of Greenpeace, advises students and professionals to apply critical thinking when investigating the properties of materials, and praises the use of vinyl as a sustainable and safe material in a new video.

This story appears on www.vinylnewsservice.com.

For a direct link to the article and video, go to: http://vinylnewsservice.com/MainMenu/News/LatestVNSNews/Environment/BenefitsofVinylProducts.aspx

After lunch that day I received this email from Robert:

Chandler,

I haven’t forgotten about you…I just had two major issues come at me over the last week or so and haven’t been able to do anything else. Ill try to get something to you next week sometime.

Rats…I then shot back the following email:

Hey,

No worries my friend; I assumed you were busy. Well, shoot me an email when you get a second—I have so much to tell you!

And to my surprised, a half an hour later I received this from Robert:

Chandler,

I’m still a bit busy but know if I don’t get back to you now, I’ll likely forget forever!? Plus I want to know about the “so much to tell you!”

I know rather little about greenpeace.org unfortunately so I can’t comment on the organization.

Regarding PVC, I’m no expert but I do know that it poses health risks at various points in its lifecycle particularly if it’s incinerated. PVC also has a terrible habit of ruining bales of other material if it’s not caught in the sorting phase (I’ve heard as little as 0.1% PVC is enough to ruin a batch of PET.) We do have a plastics expert here at the Board, his name is Edgar Rojas. If you’d like to ask him about PVC you can send him an email at (contact wishes to remain anonymous).

PVC seems to be on the chopping block every legislative session with a bill to ban it every year it seems. Obviously it’s never been passed, but there is always concern over the material, particularly in food-contact applications. PVC and PS are the two plastics that come under fire most often for their toxicity and environmental/human health effects. I don’t know what the results will be once all the science is gathered to find the true full lifecycle effects of these materials in various applications, but from what I see it doesn’t look particularly good.

Ok…your turn…

Ha!

Tune in tomorrow to learn more about recycling in America.

After sending out several emails to contacts in different organizations (who wish to remain anonymous), I received the following information about non-bottle PET recycling. Hopefully you will find this information as valuable as I did in my journey to discover why PET clamshells, blisters, trays and components are not recycled in most American communities.

Quick answers:

1. Including blister packs into PET bottle recyclate is unlikely to be good idea;
2. Clear PET trays might be technically okay to be mixed in with PET bottles – but there is a sorting problem due to PVC;
3. PET trays/clamshells/blister packs could be sorted out of the residual mixed plastics waste to make an rPET grade – although this may prove to be more restricted in markets than bottle recyclate.

PET types

Blister packs that aren’t PVC generally use a copolymer of PET called PET-G or PETG. This is softer and tougher than standard PET and can’t crystallize, so is used for some PET films and thin sheet applications because the manufacturing is easier (even though the material is a bit more expensive). ?Some clamshells and trays use PET-G, but most will use standard PET identical to that used for bottles. All ovenable frozen food trays use crystallized PET as they need to stay rigid at high temperature – this is chemically identical to bottle grade, but most frozen food trays are pigmented anyway?

PET-G can be a problem in PET recycling. A little bit probably would never be noticed, but if significant sources of PET-G were going to be used as feedstock for any particular process, this would have to be fully tested in trials by the re-processor and the end-users – recyclate for use in bottles (made by injection stretch blow molding) might not be able to accept much PET-G without quality problems, but a recyclate intended for trays or clamshells (made by sheet extrusion and thermoforming) might be fine.

PVC Issue

Getting PET packages recycled also depends on the confidence and cost of being able to extract the PET from the commingled plastics without excessive PVC contamination, which degrades at PET processing temperatures (causes yellowing, black specks and may affect food-contact status)

Since clear PVC is widely used in these sort of packages as well as PET and the two are visually indistinguishable except by inspection of the plastics code (if present) then manual pre-sorting and final checking won’t be feasible based on container shape as it is for bottles. Therefore the automatic sorting would have to start from a very high contamination level– this increases the difficulty of getting to a low enough level of PVC content.

With PET bottle recycling, it is already a little difficult to keep PVC low enough, as PVC gets into the bottle stream anyway in the form of labels and cap liners – if you tried to include trays etc, then only a few PVC packs would need to sneak through the sort process to downgrade a batch.

Hence, recyclers are hesitant to include PET clamshells, trays etc with sorted PET bottles because they might end up with lower incomes despite the higher volumes.

All this means to me that it is more sensible to try to get PET clamshells and trays from the mixed plastics fraction (after already removing bottles) and finding a market for that quality of rPET, rather than trying to sort bottles and clamshells/trays together. This is the approach being tested by WRAP (Nextek are running a project for them).

Okay…so based on this insight, it is more feasible to create a new end-market for mixed rigid plastic material than to try and integrate our PET packages into the existing PET-bottle recycling infrastructure…

That’s all for today folks; I think we should all let this information sink in. Tune in tomorrow for more discoveries about recycling in America!

Happy Friday!!!

Sorry I did not post yesterday; I was at the Dental Show at McCormick place in Chicago, doing research on how that medical industry is interpreting sustainability. 

Good times!

Anyway, the project manager from the SPC would prefer if I did not post any of our correspondences to my blog; therefore, she is working on putting me in touch with a colleague in Australia who would have the information she provided to me about recycling non-beverage PET via previous emails.

In the meantime, shall we resume our recycling narrative?

On Nov. 6^th I came into the office feeling good; I had sent out 50 of our RPET samples to the MRF at Waste Management, where they would be run through the optical sorter to see if they are “read” like PET bottles and therefore of similar material. By understanding the way our material moves through the sorting technologies at Waste Management, we will gain a better understanding of what obstacles are keeping our RPET packages from being recycled with PET bottles.

The logic is: our RPET is made out of PET bottles; therefore, why not recycle our thermoformed RPET packages along with PET bottles, to be sold back again to our material suppliers, who grind the PET bottles down and create rolls that we consequentially form into new RPET packages. Get it?

I wonder how long for the results…

I sent the educational tourguide of Recycle America, a division of Waste Management, the following email:

Hey!

I just wanted to drop you a quick email updating you on the status of our recycling initiative:

I got into contact with an IL Rep who suggested I send him 50 of our RPET clamshell samples to run through their optical sorting technology to see if our material is compatible with the PET bottle material. If so, perhaps we can find an end-of-life market for our RPET packages within the existing recycling infrastructure for PET bottle material. If not, then at least we have eliminated one of many material recovery options. I will let you know the status of the test as soon as I do.

I just wanted to follow up with you as you have been so helpful to me; I really appreciate you putting me in contact with people at WM who can help implement our recycling initiative.

Just out of curiosity, do you know who has or where there is optical sorting technology (municipality/regional)? Moreover, do you know where or by whom mixed plastic is collected (once the PET bottles have been sorted out)?

Thanks again for all your help. I can’t wait to find an end-of-life market for our packages!

By the by, do you need any information about plastic packaging as it relates to sustainability issues? I know that a lot of consumers are misinformed about the environmental attributes of different packaging materials and if you needed accurate data about plastics’ environmental advantages and disadvantages in order to inform the consumer for better buyer decisions, please let me know. I would love to provide you with a plastic packaging sustainability profile for you to educate your tour guests and give them the tools they need to identify green washing and manipulative environmental advertising.

Thanks again and I look forward to speaking with you soon!

Best,

Chandler

While working on this recycling project, I was also juggling a lot of other sustainability initiatives. At the fall members-only meeting of the SPC in Atlanta, someone mentioned greenerpackage.com to me as a great site for knowledge exchange about issues pertaining to sustainability and packaging. Ever since, I frequent this site daily, taking part in conversations and eager to get the “truth” out about the sustainability of plastic (I had conducted a ton of research about plastic versus other packaging materials in the context of sustainability and was delighted to find that because its lightweight and versatile character, it actually saves energy in manufacture, conversion, shipping, etc. when compared to more dense materials; and, plastic doesn’t comprise the most landfilled packaging material—paper does! And (I could go on and on), although plastic is made from a non-renewable energy source, it actually consumes less water, biotic and natural resources and releases less greenhouse gases into the atmosphere when compared with pulp and paper manufacturing. All this information, with references, is available at www.dordan.com under the “Sustainability” tab).

ANYWAY, I got hooked up with a bunch of people at greenerpackage.com, who enjoyed what I was doing and wanted to help Dordan and our sustainability initiatives. The business director of greenerpackage.com is one contact whom I continue to talk with; she has been a great help and continues to be a sounding board for a lot of my inquiries.

Once I described my recycling initiative to her, she suggested I get in contact with her colleague at the Sustainability Consortium, which is an industry group that works with retailers and consumer goods companies on a variety of sustainability initiatives. One initiative is the Sustainability Index—a database that identifies materials for end-of-life recycling, reuse, and recovery.

After purusing their website (www.sustainabilityconsortium.com), I sent the following email of inquiry:

Hello,

My name is Chandler Slavin—I am the Sustainability Coordinator at Dordan Manufacturing, which is a Midwestern-based customer design thermoformer of plastic clamshell and blister packages. I have been researching issues pertaining to sustainability and packaging for several months now, and am in the process of finding an end-of-life market for our plastic packaging. We currently are members of the Sustainable Packaging Coalition, which is a project of GreenBlue, and are subscribers to COMPASS, a comparative life cycle assessment tool.

As per an email from the business director of greenerpackage.com on which you were attached, I was wondering if you could provide me with information on the Sustainability Index as it relates to identification of materials for end-of-life scenarios. After visiting your web-site, I understand your approach to the Sustainability Index but am curious how this index will work with the Wal-Mart scorecard, SPC’s metrics for sustainable packaging, and the various other metrics developed by environmental groups and NGO’s. Moreover, how will packaging factor into this index, that is developed primarily for consumer goods retailers?

Moreover, how can I get involved with the Consortium as a packaging professional in the field of sustainability? How can I help further the goals of the Consortium?

Thanks for your time and I look forward to hearing from you soon!

Best,

Chandler

Have a splendid weekend! Tune in Monday for more recycling in American deliciousness!

That Monday I arrived to the office more motivated than when I had left; how can I find a way to recycle clamshell—and more specifically—thermoformed, packaging?

As I waited for feedback from the SPC in regard to what they thought about the feasibility of finding an end market for non-beverage PET flake, the phone rang, and the receptionist transferred the call to my fine cubicle.

"Jessica with Waste Management is on line one," she announced.

I picked up the line.

…five minutes later….

Jessica was super cool; she is Dordan’s contact at Waste Management who manages our waste and recycling contracts, and wanted to reach out to me because she knew I had been talking with various Waste Management employees about my initiative. And, she also provided another crumb: She suggested that I contact another Major Account Representative in IL to discuss the feasibility of my initiative; she provided his name and number.

I called him that day, eager for some direction.

Ring…ring…ring…

"Hello?"

…ten minutes later…

Hurray! A bigger bread crumb!

Apparently, what a plastic cup manufacturer in the Midwest had recently done, and he encouraged us to do, was send off some of our RPET clamshells to a Waste Management Material Recovery Facility (MRF) to see if their optical sorting technology would “read” our material like it reads the material in PET bottles. If the sorting technology couldn’t tell the difference between our RPET and the PET used in beverage bottles, then the material is close enough to theoretically be integrated into PET-beverage bales. In other words: the material is the same, which makes sense, because our RPET is certified at a 70% post-consumer regrind concentration, which means 70% comes from PET-beverages and 30% comes from virgin PET resin, give or take. Basically, if we thermoform material made out of bottles, why wouldn’t our packages then be compatible with this optical sorting technology.

The Account Representative offered to run our samples through their optical sorting technology to see if the problem with recycling non-beverage PET is due to sorting capabilities. Great!

He forwarded me the address of the MRF.

That day, I grabbed 50 of our sample as they came off the machine. Still warm with the heat from being formed, I placed them in the mail to go out with today’s post.

Groovy.

I sent the Account Rep the following email, confirming shipment.

Hey,

I just wanted to drop you a quick email letting you know that I sent out a box of 50 RPET clamshell samples to the address you provided for you to run through your optical sorting machine to see if they are compatible with the PET bottle material. If so, we can try and find an end market for our RPET clams, blisters, and thermoformed components.

Just out of curiosity, do you know where I can find information on who has optical sorting technology and where? Moreover, do you know who collects mixed plastic (that is, the plastic left over after the PET bottles have been removed) for material recovery and where?

Thanks again for all your help! I look forward to speaking with you again.

Best,

Chandler

Tune in tomorrow to learn more about recycling in America.

I felt as though I had hit a road block; while Robert’s kind words were encouraging, I felt like there was nothing I could do as an individual to create an end market for clamshells post-consumer, either as non-beverage PET flake or mixed rigid plastic flake. Perhaps on the vehicle of collaboration, we would be able to come up with the quantity necessary to create an end market for this homeless material…

I then started the following discussion on greenerpackage.com:

Where does the plastics industry go from here?

As Sean Sabre pointed out in a recent post, there is no recycling market for non-beverage PET flake i.e. the PET used in thermoformed packages (to veiw this discussion, visit http://www.greenerpackage.com/discuss/recycling/recovery_series_-_topic_2_universal_pet_recyclability_myth).

According to various contacts at Waste Management, this is because those who buy the balled PET beverage containers to recycle into other products do not want PET clams, blisters or components as it compromises the feedstock of the PET bottle flake. In other words, because PET beverage bottles have the same IV, additives and chemical properties, the quantity of that type of material is there, which allows for there to be an end market for it. Contrarily, the PET used in thermoformed packages has different properties depending on the additives used for the specific packaging application i.e. food, medical, consumer goods. Therefore, the quantity of the same type of PET is not available for the creation of an end market for this material. At the same time, however, there is a market for this type of material on the East and West coasts (“non-traditional rigid containers”) because China and other international markets undergoing industrialization buy this material for its stored energy value. In a nut shell: we can’t recycle it if the quantity is not there, which inherently means there is no market for the end life of these types of PET.

Where do we go from here? Do we, as an industry, decide on using one type of material per application i.e. one PET type for food, medical, and consumer goods in order to ensure the quantity of material necessary for the development of an end market for said material? Do we “down-cycle,” via Pyrolysis? Do we switch to PLA or other bio-resins, which require more energy to produce than traditional, fossil-based plastics and require the existence of commercial composting facilities, which are far and few a dozen? As an industry, we must collaborate if we want to reach our shared goals of sustainability.

If interested in the comments to this post, visit http://www.greenerpackage.com/discuss/thermoformed_packaging/where_does_plastic_industry_go_here

Once I reached out to the larger packaging community about my concerns as a packaging professional, I sent the following email to a project manager at the Sustainable Packaging Coalition. As the tone of my above conversation implies, I was hoping that collaboration would begin with member companies of the SPC:

Hey,

Just out of curiosity, do you have any relationship with SPI (Society of the Plastic Industry) or other packaging trade organizations? I have begun a dialogue with said organization in regard to the SPI resin identification numbers and the feasibility of recycling non-beverage PET flake i.e. clamshells, blisters and thermoform components. We are trying to figure out a way to recapture our thermoformed packages, which currently are not recycled. We can’t decide if a closed loop system would be best, as is in the case with electronics and batteries, or if working with the existing recycling infrastructure would be more beneficial.

What is the SPC’s stance on the feasibility of recycling non beverage PET flake? Do you think a project like this would be something of interest for the SPC?

Best,

Chandler

Let’s hope the SPC wants to help! Tune in tomorrow for more exciting happenings in the world of sustainable packaging initiatives!

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!