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R-Cycle Initiative Grows Along the Entire Value Chain

R-Cycle Initiative Grows Along the Entire Value Chain

The third strategic R-Cycle consortium meeting took place – due to Corona, of course, digitally as a video conference. The results of all operational activities as well as the strategic development of the initiative were presented and discussed by the respective project leaders and managing directors of the consortium members.

The focus of the meeting was on the recent expansion of the consortium in further sub-areas of the value chain of plastic packaging. Three new key partners have joined R-Cycle in the past three months.

As Kampf Schneid- und Wickeltechnik GmbH & Co. KG, with its highly specialized equipment for processing plastic film webs, is the link to packaging production, Steinert GmbH and the Erema Group are well-known global players in the directly interrelated fields of waste sorting and recyclate production.

Dr. Benedikt Brenken, Director of the R-Cycle Initiative, explains: “In the meantime, we have been able to win renowned partners in almost every value-added step along the packaging cycle. This means we now have a holistic basis for testing our data standard. Our third meeting clearly showed that a functioning circular economy is a high priority for all stakeholders around plastic packaging and that R-Cycle has enormous potential as a solution.”

The broad cross-industry participation creates a complete data set that makes the recycling-relevant properties of a packaging transparent for waste sorting. As a result, waste streams can be sorted more precisely, producing higher-quality recyclates.

 

R-Cycle follows the approach of mapping the entire value chain of plastic packaging within the initiative.

 

 

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Comexi – Leading Supplier to the Flexible Packaging Converters Industry – Joins R-cycle

Comexi – Leading Supplier to the Flexible Packaging Converters Industry – Joins R-cycle

Comexi joined the R-Cycle consortium. The specialist in solutions for the flexible packaging printing and converting industry is already working in a pilot project for high-quality recycling of flexible pouches together with R-Cycle partner Reifenhäuser. The project was started by selecting two different film recipes for two different pouch types, both based on PE raw materials only (mono material). This makes them much better to recycle than PE/PET laminates that are in common use today. The film is produced on a Reifenhäuser EVO Ultra Stretch blown-film line. Film conversion (printing and lamination) takes place at Comexi. The collaboration intends to demonstrate that harnessing the R-Cycle concept can optimize the recycling process by storing recycling-relevant production data and affixing a digital watermark on packaging to retrieve the information. This ensures a precise sorting in the recycling process in order to produce pure and high quality recyclates.

R-Cycle follows the approach to trace plastic along the entire value chain – from the raw materials to the final consumer packaging getting recycled. Comexi is positioned practically in the middle of this life cycle and will therefore use R-Cycle data for its own further processing as well as supplement the data itself.

Jordi Sahun, Chief Innovation & Technology Officer of Comexi, explains: “A part of Comexi’s vision is to turn the flexible packaging print and conversion industry into an environmentally sustainable industry. R-Cycle gives us the opportunity to play an active role in the development towards a functioning circular economy for plastic packaging.”

Dr. Benedikt Brenken, Director of the R-Cycle Initiative, adds: “It’s great to have Comexi on board as an R-Cycle consortium partner. Given the fact, we already developed an identifiable and fully recyclable All-PE Pouch within our R-Cycle pilot project, we are able to immediately intensify our activities from a profound common basis.”

 

Jordi Sahun, Chief Innovation & Technology Officer of Comexi.

 

 

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R-Cycle in Practice: First Applications Presented to the Market

R-Cycle in Practice: First Applications Presented to the Market

The fourth strategic R-Cycle consortium meeting focused on practical applications. On April 28, project managers and managing directors of the consortium members met – digitally via video conference due to Corona – and presented their operational activities. It became clear that R-Cycle is no longer a concept or a pure development project – the first applications have already found their way to two international trade fairs, where they met with lively interest.

At Hannover Messe 2021 (Digital Edition), for example, R-Cycle partner Arburg presented a “smart” turnkey system for producing sustainable PP Cups that are finished in an integrated digital printing station. All recycling-relevant production data is thereby recorded in the R-Cycle platform and can be retrieved via a data matrix code for improved waste sorting. In this way, each cup can be traced and separated by type, which is the basis for obtaining high-quality recyclates.

 

Arburg’s turnkey line produces sustainable PP Cups, for each of which a digital product passport is generated in the R-Cycle standard, which can be retrieved via data matrix code, thus enabling traceability and precise waste sorting.

 

Reifenhäuser showed another application: at Chinaplas 2021, the film specialists presented an All-PE Pouch manufactured together with partners Comexi and Wolf Verpackungsmaschinen. The pouch, made of a mono-PE composite, is fully recyclable and identifiable via the digital product passport via R-Cycle. Based on the data provided, the individual process steps can also be optimized.

Dr. Benedikt Brenken, Director R-Cycle Initiative, explains: “Presenting our solutions to a broad live audience for the first time is extremely exciting. We get direct feedback this way and new approaches and conversations arise. Sustainable packaging and digital traceability across the various stages of the value chain are a global trend. This is also reflected in particular by the high level of interest in R-Cycle at Chinaplas. Here we had significantly more positive response than we would have suspected. We discussed these and many other findings from the past quarter at management level during our fourth strategic consortium meeting and incorporated them into our roadmap accordingly.”

Reifenhäuser, Comexi and Wolf Verpackungsmaschinen jointly manufacture a fully recyclable all-PE pouch that can be identified via R-Cycle.

 

 

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MULTIVAC – the World’s Leading Manufacturer of Integrated Packaging Solutions – Becomes an R-Cycle Partner.

MULTIVAC – the World’s Leading Manufacturer of Integrated Packaging Solutions – Becomes an R-Cycle Partner.

MULTIVAC joins the cross-company initiative R-Cycle. The aim is to jointly drive forward the circular economy for plastic packaging on the basis of an open and globally applicable tracing standard. R-Cycle records all recycling-relevant information from the production process in the form of a digital product passport and makes it available for recycling. To retrieve the stored information, a machine-readable mark – for example, a QR or digital watermark code – is applied to the packaging. In this way, waste sorting systems can use market proven detection technologies to identify fully recyclable packaging and form pure fractions within the recycling process. Precise sorting and transparency regarding the exact composition (types of plastic, printing inks, adhesives, additives, etc.) are key to obtaining high-quality recyclate for high-value recycling.

Stefan Scheibel, Vice President Corporate Training & Innovation Center of the MULTIVAC Group, explains: “In our Innovation Center we are always analyzing the latest trends and advising our customers on the market requirements of tomorrow. Digitization along the value chain has enormous potential in this respect for bringing sustainable packaging into a high-quality recycling process. We think of sustainability holistically. Packaging must effectively protect goods – especially food – in order to conserve resources; at the same time, the packaging itself must be designed sustainably and effective recycling processes must be ensured. In this context, exchange with partners from all involved industrial sectors is essential.”

 

Stefan Scheibel, Vice President Corporate Training & Innovation Center of the MULTIVAC Group.

 

Dr. Benedikt Brenken, Director of the R-Cycle Initiative, adds: “With MULTIVAC, we are gaining another important partner and global player in the value cycle. Not only the material of a package, but also its contents represent important recycling-relevant information, which we capture with R-Cycle. We look forward to working together and generating new momentum in the development and implementation of the R-Cycle standard.”

“Sustainability is an integral part of our corporate strategy,” explains Guido Spix, Group President of MULTIVAC. “We are pleased that by joining the R-Cycle initiative we can support shape an industry standard and thus make a positive contribution to promoting the circular economy for plastic packaging. The exchange with upstream and downstream processes in the value chain helps us to understand the individual steps even better and to co-develop sustainable solutions.”

 

Guido Spix, Group President of MULTIVAC.

 

In addition to manufacturing packaging machines, MULTIVAC also supplies solutions for processing and cutting, marking and labeling, and also quality inspection and handling of products. The portfolio is supplemented by digital products, such as MULTIVAC Smart Services, which help to increase machine availability and thus efficiency. A digital product passport of plastic packaging can also provide valuable information for this, in order to make the packaging process more efficient, faster and therefore more sustainable.

 

 

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Aloxe Invests 50 Million Euros to Become the Independent European Leader in Recycled Pet.

Aloxe Invests 50 Million Euros to Become the Independent European Leader in Recycled Pet.

At this K Trade Fair 2022, Aloxe announces €50 million investments in Pet recycling in the 3 countries where it is already established (France, Poland, Italy). With 120 000 tons of capacity in Europe, Aloxe becomes the independent European leader in recycled Pet.

50 Million euros investment in 3 countries,

–  Opening of a new plant in France in April 2023 with a capacity of 35 000 tons and an additional capacity of 20 000 tons already planned.
–  Development of its capacity in Poland with an additional 40 000 tons of extrusion capacity starting spring 2024.
–  Ramp-up of its Italian plant.

After the acquisition of Loreco Plast Recyclage (France) in 2021 and Elcen (Poland) in August 2022, Aloxe has just completed a third acquisition in Italy.

A premium plastic supplier able to serve global and consolidated fast-moving consumer goods (fmcgs’) and plastic converters.

In a market driven by European regulation (25% recycled content in beverage bottle in 2025, 30% in 2030) the needs of the beverage industry are tremendous. And such industries as food, cosmetics, pharmaceutical or home and personal care are also committing on recycled content.

A sizeable challenge that Aloxe is now able to meet, with production sites in France, Poland and Italy, head-on to respond to this growing demand.

« We aim to partner with leading FMCG’s and plastic packaging manufacturing companies to supply them with high-quality recycled Pet; we will continue to work to support them achievetheir ambitious sustainable packaging goals » said Arnaud Piroëlle, Aloxe’s Executive Director.

A pan-european expert that secures high-quality and large volume.

In a controversial context on plastic & packaging, Aloxe is helping to make plastics a solution for a sustainable future.

The company draws on more than 20 years’ worth of expertise in recycling and produces food-grade recycled Pet. Aloxe recognizes the importance of their quality and keeping it consistent, as well as the ability to supply large quantities for pan-European customers.

 

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How Plastics Can Be Used in a Resource-Saving Way

How Plastics Can Be Used in a Resource-Saving Way

Plastics have been the subject of environmental debate for some years now. But they are also high-performance and efficient materials that, not least, make our everyday lives safer. In the case of food, for example, plastic packaging ensures hygiene and shelf life, thus reducing food waste at the same time. Plastic is also a key material for the energy revolution, as its low weight saves CO2 when used as packaging on transport routes, among other things.

The current issue of the renowned German business newspaper “Handelsblatt” is therefore devoting an enclosed special supplement “Plastics – material of the future” to the question: How can plastics be used in a resource-saving way and, above all, recycled at the end of their life and reintroduced into the raw materials cycle? New technologies are presented that optimize the manufacturing process and improve recycling.

 

Supplement – Handelsblatt – „Plastic – Material of the Future“

 

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R-Cycle Wins the German Sustainability Award 2021

R-Cycle Wins the German Sustainability Award 2021

R-Cycle – the digital product passport for sustainable plastics – receives the German Sustainability Award 2021 in the “Packaging” category. The award is conferred by the German Institute for Service Quality (DISQ), the German news channel ntv, and Dup Unternehmer (German Entrepreneurship Platform for Digitalization and Sustainability). The award is patroned by Brigitte Zypries, former Federal Minister (ret.).

Plastic packaging has become an indispensable part of our everyday lives and there is often no alternative – such as in medical technology or in the packaging of perishable foodstuffs. However, the problems associated with the growing global demand for plastic packaging cannot be overlooked and are becoming increasingly acute. For example, even in the “recycling land” of Germany, only about 6% of plastics from domestic waste are recycled to make equivalent new products. The largest percentage of over 65% is burned in waste incinerators.

One reason for the low recycling rate is the present difficulty to identify the different compositions of plastic packaging in the recycling process. Sorting is considerably improved when a digital product passport is affixed to plastic packaging to display this information. R-Cycle is such a digital product passport. It is based on an open standard and is machine-readable via special markings. R-Cycle automatically registers all recycling-related properties during packaging production and passes this information along the value chain. Waste sorting plants can then identify recyclable packaging and form recyclable fractions. This is the basis for obtaining pure and therefore high-quality recyclates as part of efforts to set up a functioning circular economy.

“We are delighted to receive this award,” says Dr. Benedikt Brenken, Director of the R-Cycle Initiative. “Digitalization and sustainability are two megatrends that we have integrated beneficially in R-Cycle. The use of a digital product passport, as also required by the European Union, offers enormous potential to increase the recycling rate of plastic packaging.”

R-Cycle is under development to market maturity by leading companies and organizations along the entire plastic-packaging life cycle. Besides improving product sustainability, manufacturers can increase their process efficiency and product quality by using a digital product passport. Detailed information about the raw materials used speeds up production and registering the product properties adds value for customers in downstream processes.

Conversio Study 2017 (Stoffstromdiagramm Kunststoffe in Deutschland) / Plastikatlas Heinrich Böll Stiftung

 

Dr. Benedikt Brenken, Director of the R-Cycle Initiative, accepts the award on behalf of the consortium.

 

 

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Start of Semi-industrial Trials for Intelligent Sorting of Packaging Waste

Start of Semi-industrial Trials for Intelligent Sorting of Packaging Waste

AIM, the European Brands Association, and the Alliance to End Plastic Waste announced their partnership to drive the next stage of development for intelligent waste sorting under the Digital Watermarks Initiative HolyGrail 2.0. They will work with the City of Copenhagen to conduct the semi-industrial test phase of the pilot. With this milestone, developers move one step closer to precision identification and sorting of plastic packaging waste through digital watermarks, with the potential to revolutionise the sorting and recycling process of plastic packaging.

R-Cycle is an active participant in “HolyGrail 2.0” as part of the “Data Management” work package to advance this initiative with know-how provided by the R-Cycle consortium and to ensure that both approaches complement each other.

Over the next four months, a prototype sorting detection unit will be installed at the Amager Resource Centre (ARC) in Copenhagen, where the trials and demonstrations with around 125.000 pieces of packaging representing up to 260 different stock-keeping units (SKUs) will be held. Engineers will test for several parameters including the speed and accuracy of the system, to ensure its ability to withstand the pressures of full-scale industrial operations. If successful, digitally watermarked products could be introduced to store shelves in Denmark, France and Germany by the first half of 2022 for in-market demonstrations and industrial-scale trials.

Digital watermarks are imperceptible codes, each the size of a postage stamp. They cover the surface of a consumer goods packaging and carry a wide range of attributes such as packaging type, material and usage. Used packaging is collected and scanned on the sorting line with a high-resolution camera which detects and decodes the digital watermark. The packaging is then sorted into corresponding streams, based on specified attributes including food, non-food or polymer types. This leads to more accurate sorting streams and higher quality recyclates to be channelled back into the plastic packaging value chain.

As part of several R-Cycle pilot projects, digital watermarks have already been applied to prototype packaging and linked to so-called digital product passports from the R-Cycle data platform, which contain recycling-relevant properties.

 

 

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BOBST Aims to Help Close the Plastic Loop With R-Cycle

BOBST Aims to Help Close the Plastic Loop With R-Cycle

BOBST, one of the world’s leading suppliers to the packaging industry, tests the R-Cycle data standard and is launching a pilot project to automatically record recycling-relevant information during the processing of plastic films.

The aim of the project is to store production data in so-called Digital Product Passports (DPP) and make the information usable for recycling the end products. This approach enables more precise waste sorting and thus the recovery of high-quality recyclate, supporting a functioning circular economy.

To accomplish this, BOBST relies on R-Cycle – the open traceability standard for sustainable plastic packaging. R-Cycle is an initiative that builds a higher standard of visibility and transparency in packaging by creating and storing measurable metrics. With better and more precise information available, the goal is to obtain a higher quality of plastic recyclate and make sustainable plastic substrates a more enticing and eco-friendly prospect for brands.

To undertake its innovative sustainability project, BOBST has selected an EXPERT K5 metallizer for its first R-Cycle trial run at its Centre of Excellence for research and development, located in Manchester.

The Expert K5 machine uses a vacuum process to finish plastic films with extremely thin coatings, such as aluminum, to create high-performance barrier properties. Films produced using this technique are significantly more recycling-friendly than conventional processes, such as lamination with much thicker aluminum films.

 

BOBST EXPERT K5 metallizer.

 

To ensure that the end products can also be efficiently recycled, which remains particularly important in food applications, the BOBST system will store information about the coating, precisely and effectively, in an R-Cycle DPP.

The technology behind this process is based on open GS1 standards for the digitization of value chains. The data record is created during the initial processing of the raw material into plastic film, which can be read and supplemented by any participant in further processing operations. Information collected can include raw materials, colors, additives or coatings, and can be accessed on both intermediate and end products through machine-readable markings.

As well as improving product sustainability, manufacturers benefit from using digital product passports in terms of process efficiency, product quality and transparency. Generating and collecting more accurate information about source materials speeds up production, while recording product properties represents significant added value for customers further downstream in the process.

Nick Copeland, R&D Director Barrier Solutions at BOBST, explains: “Digital Product Passports are key to a functioning circular economy. R-Cycle offers great potential to actively manage resources and material cycles, to ultimately ensure that sustainable packaging solutions are identified in the recycling process – and are recycled to a high quality. It is also an important digitization building block for even more efficient production processes.”

Dr. Benedikt Brenken, Director of the R-Cycle Initiative, adds: “As an industry initiative to establish an open data standard, we are delighted that BOBST, a technology leader in sustainable packaging, is exploring R-Cycle and its benefits. Transforming our current linear production economy into a true closed-loop requires digitization along the entire value chain and relevant stakeholders to drive this approach.”

 

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R-Cycle Complements Cooperation Project for a Pioneering Recycling Concept

R-Cycle Complements Cooperation Project for a Pioneering Recycling Concept

R-Cycle Partner Reifenhäuser announced, together with the key industry players Dow Packaging and Specialty Plastics (P&SP), a business unit of Dow (NYSE: DOW), HP Indigo, Cadel Deinking and Karlville, the successful delivery of the first-of-its-kind pouch-to-pouch mechanical recycling concept within a cooperation project.

The approach uses a multi-stage process to contribute to a circular economy for digitally printed pouches. Starting with a polyethylene (PE)-based barrier food pouch designed for recyclability, the project team have used mechanical recycling and deinking to create a high-quality dishwasher MDO-PE pouch containing 30 percent recycled contents and being itself suitable for recycling.

In a next step, the team is working on the digital product passport R-Cycle to allow for recycling-relevant packaging properties to be recorded and to make the pouch identifiable for high-quality recycling within post-consumer waste management.

Read the full report here: https://corporate.dow.com/en-us/news/press-releases/team-work-for-pouch-to-pouch-recycling-concept

 

 

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