Advised by: Saskia Van Gendt, Method Products PBC and David Dornfeld, UC Berkeley
Overview:
This research project was conducted Fall 2013 - Spring 2014 in collaboration with Method Products, PBC to investigate innovative options to source high quality recycled polypropylene.
Method Products PBC, the environmentally-friendly cleaning products company, sources up to 100% post-consumer recycled plastic for its packaging wherever possible and designs packaging to be recyclable at its end-of-life by selecting resins that are collected in the majority of recycling streams. However, some of Method’s packaging is not yet fully optimized: their layered pouches and polypropylene pumps and triggers do not yet contain recycled content and are not recyclable in most recycling programs. The challenge is that most of the polypropylene in the US is dyed & Method uses “natural” plastic.
There are two classifications for sources of recycled plastic:
* PCR – Post Consumer Resin: This plastic has been recycled from materials after their use by consumers (like the soda bottles in curbside recycling collection)
* PIR – Post Industrial Resin: This plastic is recycled from industrial materials or processes (such as trimmings and waste from making other bottles).
Source: Method’s Greenskeeping Toolkit
Research Objectives:
The goals of this project were to:
i. investigate innovative options to source high quality recycled polypropylene
ii. determine new end-of-life markets for polypropylene and layered pouches
iii. provide design and production recommendations to support Method’s sustainability goals
iv. consider consumer education
a. How can Method encourage consumers to re-use packaging?
b. How can Method facilitate the recovery of packaging?
c. What are alternative packaging designs or service models?
The goals of this project were to:
i. investigate innovative options to source high quality recycled polypropylene
ii. determine new end-of-life markets for polypropylene and layered pouches
iii. provide design and production recommendations to support Method’s sustainability goals
iv. consider consumer education
a. How can Method encourage consumers to re-use packaging?
b. How can Method facilitate the recovery of packaging?
c. What are alternative packaging designs or service models?
Methodology:
Literature reviews, expert interviews, and competitive benchmarking were utilized to help inform this work. Interviews were conducted with representatives of: Material Recovery Facilities (MRFs), Plastics Recyclers & Brokers, and Consultants.
A tour of the Davis Street Transfer Station in San Leandro, CA helped in understanding the challenges facing polypropylene recycling.
Findings:
The lack of recycled PP is due to the fact that:
#1: The volume of PP is not large enough to be separated & recycled on its own
#2: PP doesn’t have a high enough value to be separated by itself. Therefore, it is oftentimes output from a MRF in mixed plastic bales.
#1: The volume of PP is not large enough to be separated & recycled on its own
#2: PP doesn’t have a high enough value to be separated by itself. Therefore, it is oftentimes output from a MRF in mixed plastic bales.
The diagram below illustrates the possible flows of plastic polypropylene products.
Project Deliverables:
The outcomes of this project included an upcycling concept to promote a closed-loop recycling system. We identified the stakeholders who would be needed and developed frameworks for participation.
