PCR Recyclable Stretch Film

Both savvy shoppers and consumer packaged goods companies are placing more emphasis on sustainability, reducing waste, and using less energy. As a brand owner, your sustainability goals are more important now than ever, as consumers begin seeking out brands focused on the environment.  

When it comes to packaging, it’s no surprise that brands are looking for eco-friendly packaging. While recyclable or compostable packaging is the two most common types of sustainable packaging, there is a third choice gaining traction on the shelf – post-consumer recycled (PCR) packaging.

The full name of PCR is Post-ConsumerReydedmatral, short for PCR, which is usually made of new plastic particles after the waste plastic is recycled, sorted, cleaned and granulated by the recycling system. The plastic particles have the same structure as the plastic before recycling. When the new plastic particles are mixed with the original resin, a variety of new plastic products can be created. This approach not only reduces carbon dioxide emissions, energy consumption, and environmental pollution. PCR stands for post-consumer recycled plastic. It’s derived from end user products that have reached the end of their life cycle like PET clear water bottles, HDPE milk jugs and shopping bags. The material is collected, cleaned and sorted, processed and becomes useable in place of virgin plastic.  

Though PCR, recyclable, and compostable packaging are all sustainable packaging options, they each differ in the way that they are processed and what they can offer consumers. 

PCR packaging is manufactured with a film that is made from recycled materials. In general, PCR packaging cannot be recycled again since it’s already made from recycled materials. This allows brands to fulfill their sustainability goals, without relying on the consumer to recycle or compost the package after use. 

A package is deemed recyclable when the materials can be processed and used again.  Once the package enters the recycling stream, it is broken down into raw materials and sold to manufacturers. One potential downside of recyclable packaging is that the benefits are dependent on the consumer actually recycling the package, and knowing where to recycle the package.

Lastly, compostable packaging is packaging that breaks down completely in a compost site and leaves no toxic residue. In order for a plastic to be called compostable, it must biodegrade, or break down into carbon dioxide, water, or biomass at the same rate as cellulose (paper).  One potential downside of compostable packaging is that not all consumers have access to industrial composting facilities. 

PCR Stretch Film Technical Specifications

Specification	Cast Film
Thickness	17 / 20 / 23
Width (mm)	500
Length (m)	Up to 2300

• Post Consumer

Recycled (PCR) Film reduces the need for fossil fuels utilizing reusable materials to create the stretch film.

• Sustainability First

Reduces waste by material made with 10%-50% PCR content, recovered from post-consumables waste stream.

• Future Ready

As all industries look at how to protect the planet, the film is no different. PCR Film reduces the use of fossil fuels.

• CO2 Reduction

Using fewer fossil fuels in the production process we are minimising CO2 emissions.

• Plastic Compliance

As the EU and other countries introduce plastic taxes, using Post Consumer Recycled plastic material may reduce your tax burden.

Post Consumer Recycled Film

Available as both stretch and oriented films, the Post Consumer Recycled (PCR) film range is a great sustainable solution for your business.

The collection of waste from industrial packaging supports the production of PCR Resin which is needed to create a sustainable product of PCR film. Even the return of pre-used oriented film can be utilized to gain the resin required to make a PCR film. PCR Resin is collected from our partners with the highest grade quality considered leading to the same mechanical properties of the non-PCR film.

Due to our quality research and development, normal fossil fuel-based oriented film and PCR have the same performance qualities. By using 10%-50% PCR Resin we are confident to produce a reliable and consistent product. Manufacturing of PCR film occurs in a loop, from the recycling plant of our trusted suppliers, we produce PCR film which our customers will apply onto a pallet and eventually once used will be able to send back to the recycling plant.

It´s all about the right mixture

Mechanical properties such as stretchability, puncture resistance and holding forces are crucial for a good stretch film. The big challenge when using recycled materials is to maintain these properties. By using a well-thought-out mixture of virgin material and recycled material. The optimized formulation and processing know-how can compensate for the effects of the shortened polymer chains that are typical for recyclate. In this way achieves up to 10%-50% recycled content.

Extremely sustainable

Our machine stretch film is extremely sustainable and environmentally friendly. By using up to 10%-50% post-consumer recycled material (PCR) and its 100% recyclability, contributes significantly to the circular economy.

The Benefits of PCR Packaging 

While all eco-friendly packaging options are a step in the right direction for brands looking to be more sustainable, PCR packaging, in particular, has some benefits that are worth discussing. 

In general, PCR films are a great packaging option for brands looking for eco-friendly flexible packaging, and can be developed into stand-up pouches, lay flat pouches, and roll stock. These films can be used in most industries including confection, coffee, baked goods, snacks, pharmaceuticals, herbal remedies, pet treats, and sports nutrition.

PCR packaging also matches the quality of regular flexible packaging. PCR film can offer the same level of protection, barrier performance, and strength as regular plastic film. You can rest assured knowing that PCR film will still block light, oxygen, and other gases from penetrating the package layer and getting into your product. 

Lastly, and quite possibly the most obvious benefit is that using PCR packaging can help your company reduce its carbon footprint, lessen its impact on landfills, and meet its overall sustainability goals.

The best part? PCR packaging is a great option for brands who want to offer a sustainable solution for consumers, with no requirements or actions needed on the consumer end, unlike recyclable and compostable packaging. 

Dealing With Film Impurities
Stretch film is generally clear and free of impurities making it great for reuse. However, Sinyar has discovered that paper labels on stretch film harm the quality of PCR during the recycling process.

We encourage customers to use polymer-based labels to preserve the quality of PCR during its production. Polypropylene labels are slightly more expensive than paper labels, but the value from quality PCR production that excludes paper labels offsets the cost of paper-tainted PCR.

Quality is Key
Sinyar will never sacrifice the quality of its stretch film when replacing virgin plastic with PCR because product damage is completely unsustainable. Damaged products cannot be sold and waste money, resources, and carbon.

Helping our Partners Meet Their Sustainability Goals
Reducing product damage is crucial to meeting sustainability goals. Sinyar has a commitment to minimizing damage and costs associated with stretch wrapping loads of products.

The goal of our recycling program is to reduce virgin plastic consumption not just add PCR to our films. Our success will be measured by getting as close as possible to achieving a ratio of one pound of PCR reducing one pound of virgin plastic. Many companies add PCR to their products for acclaim and marketing, but this is almost always in addition to not in lieu of virgin material. 

FAQ:

Q: What are some of the benefits of incorporating PCR into existing formulas?

SR: Environmentally speaking, a lot! Of the 8.3 billion metric tons of plastic that have been produced in the past 60 years, 6.3 billion tons have become plastic waste and only 9 percent of that has been recycled. On top of that, an estimated 8 million metric tons of plastic end up in the oceans every year.

While there’s an urgent need to clean up the environment, there’s also the need to plug the flow of plastic waste into it. Creating a demand for and using PCR could not only help reduce existing waste but also divert plastic waste from landfills and the environment. There are various sustainable options available for plastic manufacturing but PCR has shown to be a really efficient option.

PCR has the ability to reduce the carbon footprint by 30 – 50 percent. Plus, initial production stages to create virgin plastic can be avoided with PCR, creating a reduced resource intensity. Furthermore, with the increase in public awareness, we’re seeing mandates develop to incorporate more PCR content by brand owners and consumers alike.

Q: Are there perceived notions or hesitations about PCR when it comes to incorporating it into formulations? How would you convince them to give PCR a chance?

SR: A common misconception is that PCR is of low quality because of the wider specification due to the multiple sources it can be made of. They’re prone to gels and often have a grey to green color, which is in due part to the material sources and processing steps. Additionally, they are prone to gels and often have a grey to green color because of the number of sources PCR is made of. From an optical point, haze and color are negatively impacted.

From a cost point perspective, PCR is at best cost neutral compared to virgin material with PCR typically being a bit more expensive. FDA-approved grades are available but more expensive. Having said that, it is possible to reformulate to accommodate PCR’s shortcomings. Technology is evolving and being more effective in producing PCR plastic as close as possible to virgin material in both properties and cost. As demand increases, hopefully, PCR will become less expensive

PCR, among the various sustainable options, is the most efficient in terms of providing a solution to environmental plastic waste. It can replace virgin resin and divert used material from landfills and bodies of water. The much larger challenge is getting consumers educated about PCR and changing the perception that clear plastic is not superior or denotes quality compared to a PCR plastic that might have a slightly compromised color or haze.

Q: What will help more companies incorporate PCR into their formulations?

SR: Educating the consumer and reiterating the need for us to clean up the environment. Plastic litter is a visible problem even in developed countries. It’s not a problem restricted to the Pacific or Atlantic gyres or land masses in Asia. If consumers request the use of PCR, it will force brand owners to make it a requirement which in turn will create a demand for it. Doing this would help give value to used plastic and thereby prevent them from being an environmental problem

Q: Is there a significant investment to begin using PCR?

SR: Additional ancillary equipment like blenders may be required to add PCR material to virgin material. Most PCR processes like virgin material but it’s always best to check as there have been instances where process conditions need a bit of a tweak.

Q: Does PCR have an impact on the quality of the film? It’s strength? It’s clarity? It’s overall performance?

SR: PCR material has a wider specification in terms of density, and rheological properties (IV, MI). Gels and color are the major issues associated with PCR. The presence of gels could result in a lowering of some of the mechanical properties. However, by creative reformulation, most of the above can be mitigated.