What is PCR Plastic? The Pros and Cons of PCR Packaging

What is PCR Plastic? The Pros and Cons of PCR Packaging

What is PCR Packaging?

PCR, short for post-consumer resin (post-consumer recycled), is an environment-friendly packaging option that is made from recycled plastics, most commonly PET and HDPE plastic products. Instead of being sent to a local landfill, used items such as bottles, milk jugs, buckets, and industrial products like IBC totes and polydrums can be broken down, melted and reconstructed to make a resin material that’s then added to create a new product—PCR packaging.

PCR packaging is used to propel a continuous cycle of creating various "new" products with used recycled plastics. In addition, according to the United States Environmental Protection Agency (EPA), post-consumer recycled production reduces the reliance of fossil fuels as well as raw materials for its formulation in comparison to virgin resin products.

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Pros of PCR Packaging

The recycled resin reduces the amount of waste that is landfilled and reduces the use of fossil fuels which, in turn, improves the environmental impact of plastic packaging. PCR packaging appeals to eco-conscious consumers, and, studies suggest that people, particularly generations Gen Z and millennials, are committed to having a positive impact on the environment, indicating PCR plastics are the way of the future.

PCR allows manufacturers to produce high-quality products like a virgin resin product would at competitive prices while reducing their environmental impact. The grade of PCR plastics is equally matched with regular plastic film in terms of protection, performance, and strength. Post-consumer resin blocks light, oxygen, and other gases from seeping into the package.

PCR packaging can be suitable for food-contact use if it meets the FDA Guidelines.

These plastics decrease carbon footprints (the total amount of greenhouse gases produced by our actions).

Cons of PCR Packaging

The required reheating process in creating PCR plastics can alter the color and clarity of the product depending on the amount of resin that is added. This process does not hinder the function or durability of the bottle. Manufacturers can shy away from using post-consumer resin because the dark properties of the bottle do not fit the aesthetic they want to portray for their packaging.

Benefits of PCR plastic are dependent on the consumer recycling their products.

Price of manufacturing is contingent on the amount of plastics recycled.

How Is PCR Used?

After consumers recycle their products, recycling plants sort the bottles according to their plastic type. Because PET and HDPE plastics are most commonly used to manufacture PCR products, these plastics are collected, washed and broken down into resin pellets. The resulting pellets are then reheated, molded and formed into a new product.

PCR can be added in percentages ranging from 10% to 100% along with virgin plastic depending on the manufacturer's preference.

If post-consumer resin is used to manufacture a plastic bottle, a higher percentage can impact transparency and color. Some companies choose to incorporate less PCR in their products and more virgin resin so the material can retain the look of virgin resin. For example, if a product is composed of 25 percent PCR and 75 percent virgin resin material, then the product will look more like a virgin bottle. Additionally, many PCR plastic bottles are typically intended for products that do not require transparent packaging.

What is Virgin Resin?

Virgin resin is the term for new and unused plastic resin without any recycled products to generate an original product. Due to its clean appearance and stable nature, virgin resin is heavily used to produce a wide variety of plastic products.

PIR or PCR? Reprocessed vs Recycled

PIR, or post-industrial resin, is reworked plastic produced in the manufacturing process. PIR consists of grinded resins that were collected either from extra scrap parts during the molding stage of production or finished products that did not pass the quality control standards of the original product. Despite never being used before, the material is not considered virgin because it has been put through a second reheating process.

PIR products have not reached the consumer whereas PCR products include used material that's already reached the consumer and returned.

While PIR is reprocessed resin, PCR is made of used and recycled resin. Like PCR packaging, PIR also helps decrease the amount of plastic sent to landfills as well as reduce the demand for raw materials.

Is PCR Packaging Biodegradable?

The term biodegradable is defined as the length of time it takes for plastic to fully break down and degrade by the consumption of living microorganisms such as fungi and bacteria. While PCR is a more environmentally friendly option (in comparison to virgin resin) since it's made from recycled plastic, according to The Federal Trade Commission's Green Guides, the plastic itself is not biodegradable unless it is decomposed within a year of being disposed of in landfills, incinerators and recycling plants.

How Can We Help?

If you wish to explore other eco-friendly packaging alternatives from PCR packaging to glass containers, our packaging experts can assist with finding the best product to meet your requirements. Contact us today to discuss your packaging needs!

What is it and what are the benefits?

Many of the world’s leading brands have announced commitments to incorporate more post-consumer resin (PCR) in their packaging within the next 5-10 years. This sentiment is echoed by companies in a variety of industries around the world. Post-consumer resin is one solution to curbing the growing plastic pollution problem and decreasing the depletion of natural resources.

To meet the rising demand for post-consumer resin, the return and recycling of specific types of used, empty plastic packaging by consumers is key. One of the ways Mauser Packaging Solutions addresses the increased need for post-consumer resin and supports the transformation from a linear to a circular packaging industry is through our integrated life cycle management program, which includes collection, reconditioning, recycling and manufacturing of products from PCR materials.

So, what is post-consumer resin, how is it made, and what are the benefits?

What is Post-Consumer Resin (PCR)?

According to the International Organization for Standardization’s (ISO) “Plastics Vocabulary” list, post-consumer or post-use material, is defined as “material generated by the end-users of products, that has fulfilled its intended purpose or can no longer be used (including material returned from within the distribution chain).” This differs from post-industrial, or pre-consumer material which is defined as “material diverted during a manufacturing process”.

Post-consumer resin (PCR) includes consumer packaging items such as plastic film, bottles, milk jugs, buckets, and also industrial packaging items such as IBC totes and poly drums. These items can be reprocessed into recycled plastic that’s used to make new products.

For more Is PCR Plastic Recyclableinformation, please contact us. We will provide professional answers.

How is PCR manufactured at Mauser Packaging Solutions?

When an IBC or plastic drum reaches the end of its usable life and is no longer suitable for reconditioning, the first step in the recycling process is collection through the Mauser Packaging Solutions collection program. Empty containers and used plastic components are then sorted, shredded, ground, washed, dried and repelletized as high-quality post-consumer resin in compliance to ISO : standards. We call this in-house generated PCR “RecoleneTM.”

RecoleneTM, our premium recycled resin, is used to manufacture our own components and packaging, such as the Infinity Series of products. It offers the same benefits of reusability and recyclability as virgin resin and comparable technical performance. In alone, Mauser Packaging Solutions generated more than 51,000 metric tons of post-consumer resin from empty IBCs and plastic drums returned through our collection program.

What are the benefits using PCR?

Post-consumer resin offers a lower carbon footprint compared to virgin materials. Use of PCR diverts waste from landfills, decreases the consumption of virgin raw materials, and reduces emissions while promoting the circular economy.

How can your company contribute?

With such high demand for recycled materials, collaboration among the supply chain with the packaging manufacturer, filler and end user is extremely important to establish a true circular economy.  

PCR plastic packaging is a sustainable packaging solution currently gaining traction in the pursuit of limiting the environmental impacts of product waste. Many global leading brand owners have announced their sustainability commitments to incorporate PCR plastics by -. Before adopting this solution, you should consider the challenges you might face with PCR plastics. PCR is not a perfect solution, and it comes with its unique advantages and disadvantages. First, let us discuss the basics.

What is PCR plastic?

PCR stands for Post-Consumer Recycled. Some people use PCR as Post-Consumer Resin. PCR plastics are end products of the recycling process from used plastics. There are many types of plastics in the market, but the most common PCR materials are high-density polyethylene (HDPE) and polyethylene terephthalate (PET). The amount of polypropylene (PP) collected through recycling is less than HDPE and PET, making it less available as a PCR format. However, there are growing demands for PP PCR plastics along with HDPE and PET. The benefits of using PCR, such as reduction in total carbon footprints, and reduction of waste and use of raw materials, are already well known. However, it is vital to recognize the challenges of using PCR to make the right decisions. To understand the challenges associated with PCR, first, we must understand how it is made.

The most popularly used plastic recycling system, known as mechanical recycling, requires various steps, including sorting, cleaning, shredding, melting, and remolding. After the mechanical recycling process, used plastics become PCR resin used to manufacture plastic products once again.

Consideration 1: PCR Material Quality – Degradation

Plastics are typically composed of polymers. The polymers have long-chain structures with various elements such as carbon, hydrogen, oxygen, and nitrogen. During the recycling process, the polymer chains break down, resulting in degradation. This is why it is challenging to create packaging with 100% PCR with the same durability and performance as packaging manufactured from virgin resin. Most plastic can only be recycled a few times before it becomes unusable. There has been tremendous innovation around PCR, making it possible to develop 100% PCR packaging with good performance, such as the packaging used for Colgate-Palmolive dish soap. However, it is still one of the main hurdles associated with PCR.

Consideration 2: PCR Material Quality – Impurity

In addition, not all recyclable plastics are recycled—quality matters. Plastics have not only different chemical and physical properties but also different applications. For these reasons, plastics that are collected contain various materials, sizes, shapes, and colors. Even though plastics go through an intensive sorting process, PCR resin can still result in some impurities. Therefore, recycled plastics generally must have good quality to be accepted for reprocessing. On top of the challenge of finding a steady supply of PCR, brand owners who wish to use such materials are also faced with ensuring that the supply they have found is of adequate quality.

Consideration 3: PCR Material Supply

Lastly, as mentioned above, the supply of PCR plastics cannot support the growing PCR plastic demand. According to Waste Management, 25% of materials that consumers place in recycling bins do not get recycled due to contamination. While many consumers understand the importance of recycling, there is a general lack of understanding on how to recycle products.

The chart below details how the US PCR markets have changed over the past five years, polyethylene or PET, and recycled PET or rPET.

In , China stopped importing about two billion tons of plastic trash each year. Quickly, the world realized the impact and size of our global waste issue. From to , governments implemented policies to reduce virgin plastic and brands committed to circularity goals. It is a good start but still detrimental to both supply and demand.

Current / Futuristic PCR Market:

Supply

• The current supply of PCR used in packaging is not projected to meet the demands that we have over the next few years.
• Waste recycling, recovery and collection are becoming more economically attractive. Large companies like, KW Plastics invested and expanded in new capacity, increasing supply volume and quality.
• Packaging norms are changing towards sustainable recyclable designs, ultimately increasing higher quality “circular” supply.

Demand

• Buyers and sellers now have a new opportunity with these new digital marketplaces to make trading more feasible.
• PCR packaging helps reduce the demand for raw materials and decreases the amount of plastic sent to landfills.
• PCR demands continue to increase as oil becomes more expensive and generally not wanted.

This graph below showcases the plastics and resins index have been declining since October . This is caused by the inflation directed demand of the supply chain.

Summary

In conclusion, PCR plastic is a great sustainable option. It is essential to be aware of the challenges and use PCR as one of the options to achieve sustainability goals. ZACROS has been in the flexible liquid packaging market for over 50 years. We have experience and knowledge about packaging as well as materials. We think beyond the packaging with our innovations. Contact us to learn more.

References

“Misalignment between PCR supply and demand.” Recycling Today.

“The Economic Case for Recycled Plastics Is Improving.” IndustryWeek.

“What Is PCR Plastic? The Pros and Cons of PCR Packaging.” thecarycompany.com.

For more information, please visit Post-Consumer Plastic Reuse.