ExxonMobil is going green. Well maybe that’s a stretch. But the company is
exploring the production of a type of polyethylene packaging that is easier to
recycle.
Now, it is really hard to Google® useful information on ExxonMobil. However, if you take a granular look at an Exxonmobil press release, it is possible to pick out keywords you can use to further your online research.
For example, take a look at the following ExxonMobil press release …
TIP: Whenever you find anything of interest, no matter how trivial, mine it for keywords to help refine your Google® searches. You might get lucky.
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ExxonMobil begins production on Beaumont high-performance polyethylene line
IRVING, Texas – ExxonMobil said today it started production on a new high-performance polyethylene line at its Beaumont, Texas polyethylene plant. The expansion increases plant production capacity by 65 percent or 650,000 tons per year, bringing site capacity to nearly 1.7 million tons per year.
•Increases polyethylene plant production capacity by 65 percent or 650,000 tons-per-year
•Project supported more than 2,000 temporary jobs and approximately 40 permanent jobs
•Expansion makes Texas the company’s largest polyethylene producer
This expansion builds upon supply advantages created by ExxonMobil’s two new performance polyethylene lines which began production in 2017 at the company’s manufacturing site in Mont Belvieu, Texas. Together, these multi-billion dollar investments will help meet strong global demand growth for polyethylene, particularly high-performance products used for liquid and food packaging, construction liners and agricultural films.
“The availability of new supplies of domestically produced natural gas liquids provides us with a significant advantage when expanding polyethylene production to meet worldwide demand growth,” said Karen McKee, president of ExxonMobil Chemical Company. “Our unique polyethylene products offer enhanced performance benefits to our customers, including strength and ease of processing, compared with commodity products.”
The project created 2,000 jobs during peak construction and currently supports approximately 40 permanent jobs. Operations associated with the Beaumont expansion are expected to increase regional economic activity by $20 billion in the first 13 years, according to research completed in 2015 by Impact Data Source.
Beaumont’s polyethylene plant expansion is part of ExxonMobil’s 2017 Growing the Gulf initiative, which included plans to build and expand manufacturing facilities along the U.S. Gulf Coast, creating more than 45,000 high-paying jobs across the region.
source: https://corporate.exxonmobil.com/News/Newsroom/News-releases/2019/0724_ExxonMobil-begins-production-on-Beaumont-high-performance-polyethylene-line
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Two promising keyword phrases from the press release are polyethylene, and Karen McKee.
First let’s explore polyethylene.
TIP: Google® polyethylene exxonmobil
One result ...
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ExxonMobil debuts new polyethylene technology advancements at Chinaplas
By: Stephen Moore (Plastics Today) on June 17, 2019
ExxonMobil introduced two new performance polyethylene (PE) polymers for high-quality flexible packaging, and recyclable full PE laminated packaging solutions, at the recent Chinaplas 2019 show in Guangzhou. “Advancing polyethylene technology is an important part of our commitment to helping customers grow their businesses,” said David Hergenrether, ExxonMobil Chemical vice president, polyethylene. “By working together, we can help customers create differentiated packaging solutions that offer enhanced performance and processing, while helping them to meet their sustainability goals.”
ExxonMobil supplies multiple PE resins for all-PE laminated packaging solutions.
New Exceed 2012MA performance PE polymer reportedly delivers outstanding sealing and extrusion performance for high-integrity flexible packaging films. It can enable reduced energy use, lower per unit packaging costs, and less packaging material and food waste. The resin can be used in lamination packaging, cast stretch packaging, barrier packaging and full PE laminated stand-up pouches
For high-quality coating layers used in laminates, new Exceed 0015XC performance PE polymer delivers excellent sealing performance, a broad hot-tack window and good processing. This new polymer offers easy extrusion onto substrates such as board and paper, aluminum foil, flexible films and PE-based woven fabrics. It is ideal for drink cartons, paper cups, lamitubes, flexible packaging, tarpaulins and raffia coating and also provides opportunities for downgauging.
Cost Saving Purging Best Practices for Extrusion Processors
This white paper will discuss some of the most common extrusion processing issues and will give you a framework to solve them. Our Purging Experts will explain different tips to improve changeovers, remove contamination and more.
ExxonMobil is also introducing new full PE laminated packaging solutions, containing Exceed XP, Exceed and Enable performance PE polymers. These solutions help overcome the recycling issues typically associated with conventional laminated structures.
Often comprising a mix of PET, PA, EVOH or OPP, laminated packaging structures can be challenging to recycle, due to difficulties separating the materials. The new full PE laminated solutions can be recycled with PE film where programs to collect plastic films exists, while delivering the toughness, optical properties and stiffness needed for high-quality packaging, plus material selection is simplified.
source: https://www.plasticstoday.com/content/exxonmobil-debuts-new-polyethylene-technology-advancements-chinaplas/4733792460987
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So now we have two new keyword phrases … laminated packaging, and recycling.
TIP: Google® PE laminated packaging recycling
One result …
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Multi-Material Flexible Packaging Recovery
This Industry Leadership Committee studies sustainable end-of-life solutions for multi-laminate flexible packaging.
CONTACT
tristanne.davis@greenblue.org
This committee’s mission is to provide resources for companies that want to learn more about multi-material flexible packaging recovery and learn about what actions can be taken to improve the sustainability of multi-material flexible packaging.
SPC team lead:
Tristanne Davis, Senior Manager
Flexible plastic packaging continues to grow as a material of demand. Between 2010 and 2014 global demand for flexible packaging grew 56 percent. In the U.S., flexible packaging is the fastest growing and second largest segment within the packaging industry.
While we refer to flexible packaging as whole, the types of resins, polymers and formats used to create flexible packaging varies widely. This complexity, created by using one or more types of polymers to create flexible packaging, challenges the efficient collection, separation, recycling and resale of this material. While new innovations and systems have been created to address single polymer materials, limited options for the end-of-life management of multi-materials flexible film packaging continues to challenge these types of packages.
Mono- vs Multi-Material Flexible Packaging
Mono-material flexible packaging uses one polymer only — most often polyethylene. Commonly found in plastic bags, produce bags and self-sealed food storage bags, these can currently be collected and recycled through the U.S. at store-drop-off center, or in limited municipal curbside collection programs.
Multi-material flexible packaging is composed of two or more materials joined together with adhesive or wax. By layering different materials together manufacturers can create a package with unique barrier and mechanical properties. Additionally, multi-material films are typically thinner and lighter than single (mono) material equivalents. This helps reduce demand for resources required to produce and transport packaging–including reduced greenhouse gases. Because of these advantages, in addition to cost savings, when compared to rigid plastics multi-material flexible packaging, specifically food pouches, is anticipated to be one of the fastest growing packaging formats over the next few years. However, their nature as lightweight and multi-material structures is exactly what complicates their ability for recovery, and in particular, their suitability for mechanical recycling.
Current compositions of multi-material flexible packaging vary from three layers up to nine. Because there is no standard composition, and different resins are utilized across the various layers, there is no existing program anywhere across the globe to provide for the public recovery of these materials. With an estimated 40 billion packages produced from multi-material films annually in the U.S., finding solutions to collect, sort and recover these materials is becoming of increasing interest to packaging and waste communities, as well as, consumers across the globe.
By collecting and highlighting global efforts to advance recovery options for multi-material flexible packaging, it is our aim to advance the collective understanding, and shared best practices, towards the goal of creating a sustainable solution for the management of multi-material flexible packaging at their end of life.
Mapping Challenges for Multi-Material Recycling Across the Recovery System
Design
•No standard design
Collection
•Risk of food contamination makes retail ready collection less likely
•Consumers not aware of what can be put in Store Drop-off bin
Sortation
•Too many different designs makes it impossible to identify resin composition
•Material ends up with paper because of its two dimensional format and light weight
Processing
•Many films are contaminated by food and drink
•Multiple designs on market makes it difficult to identify at post-consumer level
End Markets
•Limited upcycle markets currently available but not economically viable
•Some alternative conversion technologies require consistent volumes and quantities which are difficult to achieve from post-consumer collection
•Downcycling growing
The Chicago Tribune
Collaborative Projects
The projects listed below are initiatives designed to answer questions around the potential recovery of hard-to-recycle plastics including multi-material films.
Please note that none of these projects addressed multi-material films independently. In order to meet cost effective collection, sortation or processing, projects typically included a variety of hard-to-recycle plastics.
Materials Recovery for the Future (MRFF)
Closed Loop Foundation
Flexible Aluminum (Containing Laminate) Collection Trial
The Energy Bag
REFLEX (Recycling of Flexible Packaging) Project
Flexible Packaging in a Circular Economy (FIACE)
Circular Economy for Flexible Packaging (CEFLEX)
Materials Recovery for the Future (MRFF)
Closed Loop Foundation
Flexible Aluminum (Containing Laminate) Collection Trial
The Energy Bag
REFLEX (Recycling of Flexible Packaging) Project
Flexible Packaging in a Circular Economy (FIACE)
Circular Economy for Flexible Packaging (CEFLEX)
Materials Recovery for the Future (MRFF)
Flexible Aluminum (Containing Laminate) Collection Trial
A pilot project based within the UK established to understand the potential to develop a curbside collection and processing program for aluminum-containing packaging. The program evaluated three different communities all with different curbside programs and population.
The Energy Bag
The Hefty Energy Bag program, developed by the Dow Chemical Company, uses existing municipal waste management infrastructure to collect, sort, and direct traditionally non-recyclable plastics toward energy conversion.
Learn more
REFLEX (Recycling of Flexible Packaging) Project
Based in the UK, REFLEX was a collaborative research and development project designed to understand and address the technical barriers to mechanical recycling of flexible plastic packaging in the post-consumer waste stream. The initial aims of REFLEX were completed in 2016. Further work will now be transferred to CEFLEX to help develop and grow insights for application across all of Europe.
Flexible Packaging in a Circular Economy (FIACE)
Based in the EU, this project seeks to document the value added by flexible packaging solutions, as well as identify future opportunities which would provide the potential to further 'close the loop.' The project explores food-contact flexible films, including multi-material structures. FIACE intentionally excluded research on collection and sortation which is believed to be covered by other initiatives. Effective 2017, FIACE has merged with CEFLEX.
Circular Economy for Flexible Packaging (CEFLEX)
Circular Economy for Flexible Packaging (CEFLEX) explores the opportunities for multi-material flexible packaging across its lifecycle; particularly as it relates to being able to create a circular economy for material re-use. Data from REFLEX, the Flexible Aluminum Containing Laminate Collection Trials and FIACE all feeds into this project in order to drive a solution applicable across Europe.
Learn more
Materials Recovery for the Future (MRFF)
Materials Recovery for the Future (MRFF) is a multi-year research project designed to identify how currently unrecyclable flexible packaging could be separated at a material recycling facility (MRF) in a single stream recycling system. Additionally, the project seeks to identify the most cost-effective way to separate and create film bales for sale in order to help drive end market growth.
Learn more
Closed Loop Foundation
Project 6 of 7
Closed Loop Foundation
The Closed Loop Foundation funds research and development of technologies and business models focused on building the circular economy.
Learn more
Flexible Aluminum (Containing Laminate) Collection Trial
A pilot project based within the UK established to understand the potential to develop a curbside collection and processing program for aluminum-containing packaging. The program evaluated three different communities all with different curbside programs and population.
The Energy Bag
The Hefty Energy Bag program, developed by the Dow Chemical Company, uses existing municipal waste management infrastructure to collect, sort, and direct traditionally non-recyclable plastics toward energy conversion.
REFLEX (Recycling of Flexible Packaging) Project
Based in the UK, REFLEX was a collaborative research and development project designed to understand and address the technical barriers to mechanical recycling of flexible plastic packaging in the post-consumer waste stream. The initial aims of REFLEX were completed in 2016. Further work will now be transferred to CEFLEX to help develop and grow insights for application across all of Europe.
Flexible Packaging in a Circular Economy (FIACE)
Based in the EU, this project seeks to document the value added by flexible packaging solutions, as well as identify future opportunities which would provide the potential to further 'close the loop.' The project explores food-contact flexible films, including multi-material structures. FIACE intentionally excluded research on collection and sortation which is believed to be covered by other initiatives. Effective 2017, FIACE has merged with CEFLEX.
Circular Economy for Flexible Packaging (CEFLEX)
Circular Economy for Flexible Packaging (CEFLEX) explores the opportunities for multi-material flexible packaging across its lifecycle; particularly as it relates to being able to create a circular economy for material re-use. Data from REFLEX, the Flexible Aluminum Containing Laminate Collection Trials and FIACE all feeds into this project in order to drive a solution applicable across Europe.
Materials Recovery for the Future (MRFF)
Materials Recovery for the Future (MRFF) is a multi-year research project designed to identify how currently unrecyclable flexible packaging could be separated at a material recycling facility (MRF) in a single stream recycling system. Additionally, the project seeks to identify the most cost-effective way to separate and create film bales for sale in order to help drive end market growth.
Closed Loop Foundation
The Closed Loop Foundation funds research and development of technologies and business models focused on building the circular economy.
Flexible Aluminum (Containing Laminate) Collection Trial
A pilot project based within the UK established to understand the potential to develop a curbside collection and processing program for aluminum-containing packaging. The program evaluated three different communities all with different curbside programs and population.
This map shows the range of facilities capable of recovering pre-consumer multi-material flexible packaging waste.
Read more about this map
Know of another facility that we should add? Email us at spcinfo@greenblue.org.
Lessons Learned
Developing a sustainable solution to recover multi-material films will require solutions across all phases of the recovery system
In summarizing the key findings found in the final reports issued by the various collaborative projects, key lessons and next steps begin to emerge which offer a promising roadmap towards sustainable recycling solutions for multi-material flexible packaging.
Explore lessons learned
Industry Working Groups
Considering the significant advantages to using multi-material flexible packaging, many users and manufacturers continue to seek sustainable solutions for their end of life. Evaluating lifecycle impacts of different recovery schemes, identifying opportunities to improve processes, and seeking to drive recycling options are common objectives by a variety of industry coalitions. Below is a list of many of the current industry initiatives exploring viable solutions to increase the recovery options of multi-material packaging.
American Chemistry Council: Plastics to Fuel & Petrochemistry Alliance (PTF)
Formed in 2014, this group seeks to increase the awareness of plastics-to-fuel (PTF) technologies with the aim to establish PTF into a strong and viable alternative energy industry. Additionally, the group seeks to increase understanding of the sustainability benefits of using this technology as a recovery solution for difficult to recover plastics. Engagement is through paid membership to the Alliance.
Website: Plastics to Fuel and PetroChemistry Alliance
Flexible Packaging Resource Recovery Task Group
This ongoing working group of the Flexible Packaging Association seeks to facilitate the advancement of flexible packaging recovery, with a focus on recovery options. Only members of the Flexible Packaging Association may be engaged; although the task group and association do have a history of sharing resources and collaborating with peers on like-minded projects.
Website: Flexible Packaging Association
PACNEXT: Multi-Material Film & Bags Committee
PACNEXT launched the Multi-Material Film & Bags project committee in 2011 in order to assess opportunities for improving cost effective film recovery. The committee is currently working on a collaborative project with Stewardship Ontario, the Continuous Improvement Fund and the Canadian Plastics Industry Association. The project aims to demonstrate the feasibility of recycling post-consumer multi-material flexible packaging. They are currently performing a trial with three end-processors.
Engagement in this committee is through membership with PACNEXT
Website: PacNext
Mechanical Recycling Options
Although the technical capability exists, the challenge with existing processes for mechanical recycling of multi-material flexible packaging is the need to know what the incoming resin composition is and keeping it consistent and relatively clean. As more information and processes are tested for effective collection and sortation, wider application of these technologies may exist.
Other End-of-Life Options
Recovery options for multi-material flexible packaging includes more than just recycling. Creative thinking in design and end products can permit for increased opportunity.
Chemical Recycling: The chemical reconstitution of plastic films to a synthetic oil. This is done by heating the plastic at high temperatures in a chamber that is void of oxygen. Once converted into synthesis oil, a variety of end products may be created.
Emerging research on the best available technologies suggests this may be one of the most sustainable and viable options currently available for the end of life management of multi-material flexible packaging. However, most waste-to-fuel technologies are still in the pilot stage and the economics of the market are still emerging. Sortation and collection of significant volumes is still a challenge. The processing of multi-material flexible packaging only is unlikely to produce sufficient volume, additional plastics to supplement processing demand is likely.
Waste-to-energy: The process of generating energy in the form of electricity and/or heat from the combustion of mixed waste, including multi-material flexible packaging left for disposal.
While waste-to-energy is a commonly accepted practice in many European countries, it is less popular in North America. Access to facilities may be limited and the ability to re-use materials is eliminated.
Compostability and composting: The ability to create multi-material compostable films is another opportunity to consider. According to European Standard EN 13432, and supported by ATSM D6400, compostable films must breakdown a minimum of 90% into CO2, water and minerals within an industrial composting setting within six months. Additionally, they must not leave any harmful residue behind. Films designated to be compostable can be labelled by either the European OK Compost label, the Biodegradable Products Institute(BPI) label, or the SPC’s How2Compost label, after proving that they pass ASTM D6400 requirements in an approved laboratory test.
While compostability may be an option, collection and acceptance of compostable films still remains limited in most municipalities, and access to industrial composting is significantly restricted as a result of limited permitted facilities.
source: https://sustainablepackaging.org/committees/multi-material-flexible-packaging-recovery/
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Finally, consider Karen McKee, currently president of ExxonMobil Chemical Company (see the press release at the top of this post.) She appears to be a rising star in the ExxonMobil enterprise.
TIP: Google® Karen McKee exxonmobil
One result ...
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Karen McKee
Senior Vice President
Basic Chemicals, Integration & Growth
ExxonMobil Chemical Company
Spring, TX
Karen McKee is Senior Vice President ExxonMobil Chemical Company. In this position, she manages the company’s global Basic Chemicals and Catalysts & Licensing businesses. Her responsibilities also include integration with Exxon Mobil Corporation and Growth Ventures (www.gulfcoastgv.com/).
Karen joined the company in Great Britain in 1990, where she held a range of assignments in Chemical, Manufacturing and Refining. Following a variety of business positions based in Brussels, Belgium and Houston, Texas, she was appointed Vice President of the Adhesion Industry Global Business Unit in 2007. In 2010 she became Vice President of Operations for Lubricants & Specialties and subsequently for Fuels, Lubricants & Specialties, based in Fairfax, Virginia. She was appointed Executive Assistant to the Chairman, based in Irving,
Texas, in 2013, and became Vice President of Basic Chemicals in 2014. She assumed the position of Senior Vice President in 2017.
She co-chaired the Downstream Women’s Leadership Team and currently chairs the Chemical Women’s Leadership Team for executive women in ExxonMobil.
Karen has a master’s degree in chemical engineering from The University of Nottingham, England. She and her husband Mark, also an ExxonMobil employee, have two daughters.
source: https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&uact=8&ved=2ahUKEwi6tuO4uNjjAhVRUK0KHe8bBB8QFjABegQIBBAC&url=https%3A%2F%2Fwww.exxonmobilchemical.com%2F~%2Fmedia%2Famer%2Fus%2Fchem%2Fmicsellaneous%2Fexecutive_bio_karen_mckee_en.pdf&usg=AOvVaw1lpI-JLIj0-62y-o6kNe4X
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Now, it is really hard to Google® useful information on ExxonMobil. However, if you take a granular look at an Exxonmobil press release, it is possible to pick out keywords you can use to further your online research.
For example, take a look at the following ExxonMobil press release …
TIP: Whenever you find anything of interest, no matter how trivial, mine it for keywords to help refine your Google® searches. You might get lucky.
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ExxonMobil begins production on Beaumont high-performance polyethylene line
IRVING, Texas – ExxonMobil said today it started production on a new high-performance polyethylene line at its Beaumont, Texas polyethylene plant. The expansion increases plant production capacity by 65 percent or 650,000 tons per year, bringing site capacity to nearly 1.7 million tons per year.
•Increases polyethylene plant production capacity by 65 percent or 650,000 tons-per-year
•Project supported more than 2,000 temporary jobs and approximately 40 permanent jobs
•Expansion makes Texas the company’s largest polyethylene producer
This expansion builds upon supply advantages created by ExxonMobil’s two new performance polyethylene lines which began production in 2017 at the company’s manufacturing site in Mont Belvieu, Texas. Together, these multi-billion dollar investments will help meet strong global demand growth for polyethylene, particularly high-performance products used for liquid and food packaging, construction liners and agricultural films.
“The availability of new supplies of domestically produced natural gas liquids provides us with a significant advantage when expanding polyethylene production to meet worldwide demand growth,” said Karen McKee, president of ExxonMobil Chemical Company. “Our unique polyethylene products offer enhanced performance benefits to our customers, including strength and ease of processing, compared with commodity products.”
The project created 2,000 jobs during peak construction and currently supports approximately 40 permanent jobs. Operations associated with the Beaumont expansion are expected to increase regional economic activity by $20 billion in the first 13 years, according to research completed in 2015 by Impact Data Source.
Beaumont’s polyethylene plant expansion is part of ExxonMobil’s 2017 Growing the Gulf initiative, which included plans to build and expand manufacturing facilities along the U.S. Gulf Coast, creating more than 45,000 high-paying jobs across the region.
source: https://corporate.exxonmobil.com/News/Newsroom/News-releases/2019/0724_ExxonMobil-begins-production-on-Beaumont-high-performance-polyethylene-line
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Two promising keyword phrases from the press release are polyethylene, and Karen McKee.
First let’s explore polyethylene.
TIP: Google® polyethylene exxonmobil
One result ...
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ExxonMobil debuts new polyethylene technology advancements at Chinaplas
By: Stephen Moore (Plastics Today) on June 17, 2019
ExxonMobil introduced two new performance polyethylene (PE) polymers for high-quality flexible packaging, and recyclable full PE laminated packaging solutions, at the recent Chinaplas 2019 show in Guangzhou. “Advancing polyethylene technology is an important part of our commitment to helping customers grow their businesses,” said David Hergenrether, ExxonMobil Chemical vice president, polyethylene. “By working together, we can help customers create differentiated packaging solutions that offer enhanced performance and processing, while helping them to meet their sustainability goals.”
ExxonMobil supplies multiple PE resins for all-PE laminated packaging solutions.
New Exceed 2012MA performance PE polymer reportedly delivers outstanding sealing and extrusion performance for high-integrity flexible packaging films. It can enable reduced energy use, lower per unit packaging costs, and less packaging material and food waste. The resin can be used in lamination packaging, cast stretch packaging, barrier packaging and full PE laminated stand-up pouches
For high-quality coating layers used in laminates, new Exceed 0015XC performance PE polymer delivers excellent sealing performance, a broad hot-tack window and good processing. This new polymer offers easy extrusion onto substrates such as board and paper, aluminum foil, flexible films and PE-based woven fabrics. It is ideal for drink cartons, paper cups, lamitubes, flexible packaging, tarpaulins and raffia coating and also provides opportunities for downgauging.
Cost Saving Purging Best Practices for Extrusion Processors
This white paper will discuss some of the most common extrusion processing issues and will give you a framework to solve them. Our Purging Experts will explain different tips to improve changeovers, remove contamination and more.
ExxonMobil is also introducing new full PE laminated packaging solutions, containing Exceed XP, Exceed and Enable performance PE polymers. These solutions help overcome the recycling issues typically associated with conventional laminated structures.
Often comprising a mix of PET, PA, EVOH or OPP, laminated packaging structures can be challenging to recycle, due to difficulties separating the materials. The new full PE laminated solutions can be recycled with PE film where programs to collect plastic films exists, while delivering the toughness, optical properties and stiffness needed for high-quality packaging, plus material selection is simplified.
source: https://www.plasticstoday.com/content/exxonmobil-debuts-new-polyethylene-technology-advancements-chinaplas/4733792460987
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So now we have two new keyword phrases … laminated packaging, and recycling.
TIP: Google® PE laminated packaging recycling
One result …
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Multi-Material Flexible Packaging Recovery
This Industry Leadership Committee studies sustainable end-of-life solutions for multi-laminate flexible packaging.
CONTACT
tristanne.davis@greenblue.org
This committee’s mission is to provide resources for companies that want to learn more about multi-material flexible packaging recovery and learn about what actions can be taken to improve the sustainability of multi-material flexible packaging.
SPC team lead:
Tristanne Davis, Senior Manager
Flexible plastic packaging continues to grow as a material of demand. Between 2010 and 2014 global demand for flexible packaging grew 56 percent. In the U.S., flexible packaging is the fastest growing and second largest segment within the packaging industry.
While we refer to flexible packaging as whole, the types of resins, polymers and formats used to create flexible packaging varies widely. This complexity, created by using one or more types of polymers to create flexible packaging, challenges the efficient collection, separation, recycling and resale of this material. While new innovations and systems have been created to address single polymer materials, limited options for the end-of-life management of multi-materials flexible film packaging continues to challenge these types of packages.
Mono- vs Multi-Material Flexible Packaging
Mono-material flexible packaging uses one polymer only — most often polyethylene. Commonly found in plastic bags, produce bags and self-sealed food storage bags, these can currently be collected and recycled through the U.S. at store-drop-off center, or in limited municipal curbside collection programs.
Multi-material flexible packaging is composed of two or more materials joined together with adhesive or wax. By layering different materials together manufacturers can create a package with unique barrier and mechanical properties. Additionally, multi-material films are typically thinner and lighter than single (mono) material equivalents. This helps reduce demand for resources required to produce and transport packaging–including reduced greenhouse gases. Because of these advantages, in addition to cost savings, when compared to rigid plastics multi-material flexible packaging, specifically food pouches, is anticipated to be one of the fastest growing packaging formats over the next few years. However, their nature as lightweight and multi-material structures is exactly what complicates their ability for recovery, and in particular, their suitability for mechanical recycling.
Current compositions of multi-material flexible packaging vary from three layers up to nine. Because there is no standard composition, and different resins are utilized across the various layers, there is no existing program anywhere across the globe to provide for the public recovery of these materials. With an estimated 40 billion packages produced from multi-material films annually in the U.S., finding solutions to collect, sort and recover these materials is becoming of increasing interest to packaging and waste communities, as well as, consumers across the globe.
By collecting and highlighting global efforts to advance recovery options for multi-material flexible packaging, it is our aim to advance the collective understanding, and shared best practices, towards the goal of creating a sustainable solution for the management of multi-material flexible packaging at their end of life.
Mapping Challenges for Multi-Material Recycling Across the Recovery System
Design
•No standard design
Collection
•Risk of food contamination makes retail ready collection less likely
•Consumers not aware of what can be put in Store Drop-off bin
Sortation
•Too many different designs makes it impossible to identify resin composition
•Material ends up with paper because of its two dimensional format and light weight
Processing
•Many films are contaminated by food and drink
•Multiple designs on market makes it difficult to identify at post-consumer level
End Markets
•Limited upcycle markets currently available but not economically viable
•Some alternative conversion technologies require consistent volumes and quantities which are difficult to achieve from post-consumer collection
•Downcycling growing
The Chicago Tribune
Collaborative Projects
The projects listed below are initiatives designed to answer questions around the potential recovery of hard-to-recycle plastics including multi-material films.
Please note that none of these projects addressed multi-material films independently. In order to meet cost effective collection, sortation or processing, projects typically included a variety of hard-to-recycle plastics.
Materials Recovery for the Future (MRFF)
Closed Loop Foundation
Flexible Aluminum (Containing Laminate) Collection Trial
The Energy Bag
REFLEX (Recycling of Flexible Packaging) Project
Flexible Packaging in a Circular Economy (FIACE)
Circular Economy for Flexible Packaging (CEFLEX)
Materials Recovery for the Future (MRFF)
Closed Loop Foundation
Flexible Aluminum (Containing Laminate) Collection Trial
The Energy Bag
REFLEX (Recycling of Flexible Packaging) Project
Flexible Packaging in a Circular Economy (FIACE)
Circular Economy for Flexible Packaging (CEFLEX)
Materials Recovery for the Future (MRFF)
Flexible Aluminum (Containing Laminate) Collection Trial
A pilot project based within the UK established to understand the potential to develop a curbside collection and processing program for aluminum-containing packaging. The program evaluated three different communities all with different curbside programs and population.
The Energy Bag
The Hefty Energy Bag program, developed by the Dow Chemical Company, uses existing municipal waste management infrastructure to collect, sort, and direct traditionally non-recyclable plastics toward energy conversion.
Learn more
REFLEX (Recycling of Flexible Packaging) Project
Based in the UK, REFLEX was a collaborative research and development project designed to understand and address the technical barriers to mechanical recycling of flexible plastic packaging in the post-consumer waste stream. The initial aims of REFLEX were completed in 2016. Further work will now be transferred to CEFLEX to help develop and grow insights for application across all of Europe.
Flexible Packaging in a Circular Economy (FIACE)
Based in the EU, this project seeks to document the value added by flexible packaging solutions, as well as identify future opportunities which would provide the potential to further 'close the loop.' The project explores food-contact flexible films, including multi-material structures. FIACE intentionally excluded research on collection and sortation which is believed to be covered by other initiatives. Effective 2017, FIACE has merged with CEFLEX.
Circular Economy for Flexible Packaging (CEFLEX)
Circular Economy for Flexible Packaging (CEFLEX) explores the opportunities for multi-material flexible packaging across its lifecycle; particularly as it relates to being able to create a circular economy for material re-use. Data from REFLEX, the Flexible Aluminum Containing Laminate Collection Trials and FIACE all feeds into this project in order to drive a solution applicable across Europe.
Learn more
Materials Recovery for the Future (MRFF)
Materials Recovery for the Future (MRFF) is a multi-year research project designed to identify how currently unrecyclable flexible packaging could be separated at a material recycling facility (MRF) in a single stream recycling system. Additionally, the project seeks to identify the most cost-effective way to separate and create film bales for sale in order to help drive end market growth.
Learn more
Closed Loop Foundation
Project 6 of 7
Closed Loop Foundation
The Closed Loop Foundation funds research and development of technologies and business models focused on building the circular economy.
Learn more
Flexible Aluminum (Containing Laminate) Collection Trial
A pilot project based within the UK established to understand the potential to develop a curbside collection and processing program for aluminum-containing packaging. The program evaluated three different communities all with different curbside programs and population.
The Energy Bag
The Hefty Energy Bag program, developed by the Dow Chemical Company, uses existing municipal waste management infrastructure to collect, sort, and direct traditionally non-recyclable plastics toward energy conversion.
REFLEX (Recycling of Flexible Packaging) Project
Based in the UK, REFLEX was a collaborative research and development project designed to understand and address the technical barriers to mechanical recycling of flexible plastic packaging in the post-consumer waste stream. The initial aims of REFLEX were completed in 2016. Further work will now be transferred to CEFLEX to help develop and grow insights for application across all of Europe.
Flexible Packaging in a Circular Economy (FIACE)
Based in the EU, this project seeks to document the value added by flexible packaging solutions, as well as identify future opportunities which would provide the potential to further 'close the loop.' The project explores food-contact flexible films, including multi-material structures. FIACE intentionally excluded research on collection and sortation which is believed to be covered by other initiatives. Effective 2017, FIACE has merged with CEFLEX.
Circular Economy for Flexible Packaging (CEFLEX)
Circular Economy for Flexible Packaging (CEFLEX) explores the opportunities for multi-material flexible packaging across its lifecycle; particularly as it relates to being able to create a circular economy for material re-use. Data from REFLEX, the Flexible Aluminum Containing Laminate Collection Trials and FIACE all feeds into this project in order to drive a solution applicable across Europe.
Materials Recovery for the Future (MRFF)
Materials Recovery for the Future (MRFF) is a multi-year research project designed to identify how currently unrecyclable flexible packaging could be separated at a material recycling facility (MRF) in a single stream recycling system. Additionally, the project seeks to identify the most cost-effective way to separate and create film bales for sale in order to help drive end market growth.
Closed Loop Foundation
The Closed Loop Foundation funds research and development of technologies and business models focused on building the circular economy.
Flexible Aluminum (Containing Laminate) Collection Trial
A pilot project based within the UK established to understand the potential to develop a curbside collection and processing program for aluminum-containing packaging. The program evaluated three different communities all with different curbside programs and population.
This map shows the range of facilities capable of recovering pre-consumer multi-material flexible packaging waste.
Read more about this map
Know of another facility that we should add? Email us at spcinfo@greenblue.org.
Lessons Learned
Developing a sustainable solution to recover multi-material films will require solutions across all phases of the recovery system
In summarizing the key findings found in the final reports issued by the various collaborative projects, key lessons and next steps begin to emerge which offer a promising roadmap towards sustainable recycling solutions for multi-material flexible packaging.
Explore lessons learned
Industry Working Groups
Considering the significant advantages to using multi-material flexible packaging, many users and manufacturers continue to seek sustainable solutions for their end of life. Evaluating lifecycle impacts of different recovery schemes, identifying opportunities to improve processes, and seeking to drive recycling options are common objectives by a variety of industry coalitions. Below is a list of many of the current industry initiatives exploring viable solutions to increase the recovery options of multi-material packaging.
American Chemistry Council: Plastics to Fuel & Petrochemistry Alliance (PTF)
Formed in 2014, this group seeks to increase the awareness of plastics-to-fuel (PTF) technologies with the aim to establish PTF into a strong and viable alternative energy industry. Additionally, the group seeks to increase understanding of the sustainability benefits of using this technology as a recovery solution for difficult to recover plastics. Engagement is through paid membership to the Alliance.
Website: Plastics to Fuel and PetroChemistry Alliance
Flexible Packaging Resource Recovery Task Group
This ongoing working group of the Flexible Packaging Association seeks to facilitate the advancement of flexible packaging recovery, with a focus on recovery options. Only members of the Flexible Packaging Association may be engaged; although the task group and association do have a history of sharing resources and collaborating with peers on like-minded projects.
Website: Flexible Packaging Association
PACNEXT: Multi-Material Film & Bags Committee
PACNEXT launched the Multi-Material Film & Bags project committee in 2011 in order to assess opportunities for improving cost effective film recovery. The committee is currently working on a collaborative project with Stewardship Ontario, the Continuous Improvement Fund and the Canadian Plastics Industry Association. The project aims to demonstrate the feasibility of recycling post-consumer multi-material flexible packaging. They are currently performing a trial with three end-processors.
Engagement in this committee is through membership with PACNEXT
Website: PacNext
Mechanical Recycling Options
Although the technical capability exists, the challenge with existing processes for mechanical recycling of multi-material flexible packaging is the need to know what the incoming resin composition is and keeping it consistent and relatively clean. As more information and processes are tested for effective collection and sortation, wider application of these technologies may exist.
Other End-of-Life Options
Recovery options for multi-material flexible packaging includes more than just recycling. Creative thinking in design and end products can permit for increased opportunity.
Chemical Recycling: The chemical reconstitution of plastic films to a synthetic oil. This is done by heating the plastic at high temperatures in a chamber that is void of oxygen. Once converted into synthesis oil, a variety of end products may be created.
Emerging research on the best available technologies suggests this may be one of the most sustainable and viable options currently available for the end of life management of multi-material flexible packaging. However, most waste-to-fuel technologies are still in the pilot stage and the economics of the market are still emerging. Sortation and collection of significant volumes is still a challenge. The processing of multi-material flexible packaging only is unlikely to produce sufficient volume, additional plastics to supplement processing demand is likely.
Waste-to-energy: The process of generating energy in the form of electricity and/or heat from the combustion of mixed waste, including multi-material flexible packaging left for disposal.
While waste-to-energy is a commonly accepted practice in many European countries, it is less popular in North America. Access to facilities may be limited and the ability to re-use materials is eliminated.
Compostability and composting: The ability to create multi-material compostable films is another opportunity to consider. According to European Standard EN 13432, and supported by ATSM D6400, compostable films must breakdown a minimum of 90% into CO2, water and minerals within an industrial composting setting within six months. Additionally, they must not leave any harmful residue behind. Films designated to be compostable can be labelled by either the European OK Compost label, the Biodegradable Products Institute(BPI) label, or the SPC’s How2Compost label, after proving that they pass ASTM D6400 requirements in an approved laboratory test.
While compostability may be an option, collection and acceptance of compostable films still remains limited in most municipalities, and access to industrial composting is significantly restricted as a result of limited permitted facilities.
source: https://sustainablepackaging.org/committees/multi-material-flexible-packaging-recovery/
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Finally, consider Karen McKee, currently president of ExxonMobil Chemical Company (see the press release at the top of this post.) She appears to be a rising star in the ExxonMobil enterprise.
TIP: Google® Karen McKee exxonmobil
One result ...
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Karen McKee
Senior Vice President
Basic Chemicals, Integration & Growth
ExxonMobil Chemical Company
Spring, TX
Karen McKee is Senior Vice President ExxonMobil Chemical Company. In this position, she manages the company’s global Basic Chemicals and Catalysts & Licensing businesses. Her responsibilities also include integration with Exxon Mobil Corporation and Growth Ventures (www.gulfcoastgv.com/).
Karen joined the company in Great Britain in 1990, where she held a range of assignments in Chemical, Manufacturing and Refining. Following a variety of business positions based in Brussels, Belgium and Houston, Texas, she was appointed Vice President of the Adhesion Industry Global Business Unit in 2007. In 2010 she became Vice President of Operations for Lubricants & Specialties and subsequently for Fuels, Lubricants & Specialties, based in Fairfax, Virginia. She was appointed Executive Assistant to the Chairman, based in Irving,
Texas, in 2013, and became Vice President of Basic Chemicals in 2014. She assumed the position of Senior Vice President in 2017.
She co-chaired the Downstream Women’s Leadership Team and currently chairs the Chemical Women’s Leadership Team for executive women in ExxonMobil.
Karen has a master’s degree in chemical engineering from The University of Nottingham, England. She and her husband Mark, also an ExxonMobil employee, have two daughters.
source: https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&uact=8&ved=2ahUKEwi6tuO4uNjjAhVRUK0KHe8bBB8QFjABegQIBBAC&url=https%3A%2F%2Fwww.exxonmobilchemical.com%2F~%2Fmedia%2Famer%2Fus%2Fchem%2Fmicsellaneous%2Fexecutive_bio_karen_mckee_en.pdf&usg=AOvVaw1lpI-JLIj0-62y-o6kNe4X
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