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Towards a circular packaging industry

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12 Jan, 2024

This post was originally published on Sustainability Matters

While the legislative process got underway in 2023, it is uncertain whether the subsequent trilogue process, in which the European Council, Parliament and Commission must find a final compromise, will be completed before the next European elections in June 2024. In pursuing this legislative update, the European Commission aims to achieve three main goals.

The first is to prevent packaging waste from being created in the first place by placing restrictions on unnecessary packaging and favouring reusable and refillable solutions. The second is for a closed recycling loop to ensure that all packaging on the EU market is reusable or recyclable in a commercially viable manner by 2030. Thirdly, the Commission wants to reduce the demand for primary raw materials by creating a functioning market for secondary raw materials — to this end, it will set compulsory targets to increase the amount of recycled plastics in packaging materials.

Industry takes action

While the ambitiousness of the PPWR might have caused debate within the packaging industry, there are many associations and businesses in the field that are pursuing their own innovative developments to further the creation of a circular economy. This was apparent at the 2023 interpack expo, whose theme of a circular economy drew a large number of exhibitors focused on solutions for effective recycling and the use of recycled materials in packaging production.

Recently, the association of European plastics producers, Plastics Europe, released an action plan for plastics production without fossil resources. While it may not be possible to eliminate the use of these materials entirely, the so-called Plastics Transition Roadmap shows how 65% of fossil resources in plastics production can be replaced by circular feedstocks from biomass, recycled materials and carbon capture by 2050.

“The Plastics Transition Roadmap, which we developed together with Deloitte, shows how we can reduce CO2 emissions in the plastics value chain by 28% by 2030 and transform the industry into an ecofriendly circular economy by 2050,” said Ingemar Bühler, Managing Director of Plastics Europe Germany.

“With the support of the German Government and the European Commission, European plastics manufacturers could increase the share of circular feedstocks in plastics production to 25% by 2030 and 65% by 2050.”

Reducing plastic usage wherever possible

interpack exhibitor Greiner Packaging is working to cut down on plastics through its K3 packaging solutions (cardboard-plastic combinations). With its latest development, the K3 r100 cup, the cup’s cardboard wrap separates itself from the unprinted plastic cup on its own during the waste collection process, making it possible to recycle both materials. Additionally, the company’s thermoformed cups are already labelled in the mould using the in-mould labelling (IML) process and weigh about 25% less than an injection-moulded equivalent.

Plastics manufacturers such as Joma from Austria are also increasingly developing recyclable solutions, such as a spice grinder showcased at interpack from Joma’s re:cycle range, which is made of 100% recycled PET. rPET is currently the only plastic with a certified circular economy that is approved for direct contact with food.

Cardboard packaging with barrier properties and without aluminium

The trend towards circular solutions applies to other packaging materials too. Drinks cartons are one example: Swiss manufacturer SIG has developed a full-barrier packaging material for aseptic carton packaging solutions that does not require an aluminium layer.

The new material, called SIG Terra Alu-free + Full Barrier, can also be used for oxygen-sensitive products such as juices thanks to the full-barrier protection. It has netted the company a design for circularity award from 4evergreen, an association of over 100 manufacturers, designers, brand owners, researchers and recyclers.

Driven by the belief that packaging recyclability begins with good design, 4evergreen published the second edition of its Circularity by Design Guidelines in the European summer of 2023. These featured new guidance for sustainable beverage packaging design.

Categorising materials through state-of-the-art tech

Where did the raw materials used in packaging come from? When and where were they processed, and what exactly were they processed into? Shampoo bottles, cereal liners and other packaging solutions often have a complex structure consisting of different materials.

In order to recycle effectively, businesses need transparency about the type, origin and processing of the raw materials used, but at present there is no standardised recording or structured supply of information about recycling in plastics production processes. To make this easier going forward, GS1 Germany has joined forces with stakeholders from the plastics industry to develop the Circular Plastics Traceability guidelines for standardised collection and structured sharing of data relevant to recycling. A common data framework now enables all partners involved to share consistent data with each other and to trace back the journey of each plastic through the loop system.

“At R-Cycle, as a development partner and user of the new GS1 Germany guidelines, we offer a standardised IT infrastructure for data sharing and transparency throughout the life cycle of plastics. The data is saved automatically in line with the Circular Plastics Traceability guidelines and can be shared with all parties along the value chain,” said Benedikt Brenken, Director of R-Cycle.

Additionally, German company Polysecure has developed Sort4Circle, a new sorting technology that separates different types of packaging containing polyethylene (food, cosmetic, detergent, monolayer, multilayer, etc) in line with relevant specifications.

Making film from seaweed

A host of research projects are exploring possible applications for renewable raw materials. This includes German company Brabender, which together with Dresden University of Technology is using marine algae to produce biodegradable film that simply dissolves after use.

“At [the 2023] interpack, we exhibited the conversion process from seaweed to finished packaging. Seaweed can be used, for example, to create film for packaging laundry capsules or dishwasher tablets,” said Ludwig Schmidtchen, head of the seaweed polymer project at Brabender.

As well as being water-soluble and suitable for injection moulding, the material can also be shaped as desired and is suitable for the production of sealable films. Brabender’s ‘Carraphane’ is an example of the circular economy in action. According to the company, it is produced from seaweed without waste and with minimal resource usage before being put through an extrusion process.

The film produced in this manner contains all the nutrients that are also present in the initial plant. The films biodegrade after a short time, with all the constituent components returning to nature. The seaweed material also has a significantly smaller environmental footprint than conventional plastics and bioplastics made from other renewable feedstocks.

Image credit: iStock.com/Nikita Burdenkov

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Urban 'placemaking' focus for $85m recreation centre

Urban 'placemaking' focus for $85m recreation centre

Sydney developer Billbergia Group has announced the Rhodes Recreation Centre — an $85 million, 9200 m2 multi-purpose community hub in Sydney’s Inner West.

Located at 6 Gauthorpe St and designed by architectural firm SJB, the recreation centre is in a three-level podium building beneath two high-rise residential towers — the 48-level Peake and 43-level Oasis. Together, they form stage two of the developer’s Rhodes Central Masterplan — a $3 billion, three-stage town centre project.

The Rhodes Recreation Centre was delivered under a $97 million Voluntary Planning Agreement (VPA) between the developer and City of Canada Bay Council. It will be handed over to council next month and is set to open later this year. Once complete, the masterplan will have delivered 25,000 m2 of dedicated public amenity, including retail, community facilities and open space.

With the NSW Government’s housing reforms set to address the housing shortage, the recreation centre will reflect the importance of ‘placemaking’ — a collaborative approach to designing and managing public spaces that enhances community wellbeing and fosters connections between people and their environment — in planning new urban communities.

It also presents a pathway for public and private sectors to collaborate and create social infrastructure while increasing housing supply in fast-growing suburbs.

The recreation centre is set to add vibrancy and pedestrian activity to the local streetscape, providing a diverse range of facilities that enhance the livability of the evolving suburb. These community amenities include two full-sized indoor sports courts, a gymnastics centre, a 70-place childcare centre, a community lounge, allied health services, and bookable spaces for local groups and events. It also provides a gym with cardio equipment, weights, group fitness rooms, a creche and an outdoor terrace, alongside a range of sustainability features.

Facilities at the Rhodes Recreation Centre. Images supplied.

“Rhodes Recreation Centre is the community heart of our high-density TOD development, bringing to life Billbergia’s vision for a future-focused, livable urban environment that prioritises amenity, not just density,” said Saul Moran, Development Director – Planning and Design at Billbergia.

The amenities within the two residential towers include a swimming pool, spa, sauna, children’s play area, library and theatre rooms. Pedestrian connections and through-site links provide access to Rhodes railway station and the Homebush Bay waterfront.

“The Rhodes Recreation Centre stands as a benchmark in successful public–private collaboration. Through a VPA with Canada Bay Council, we’ve created a pathway to unlock additional housing supply while delivering significant, lasting community infrastructure. It’s a clear demonstration of how thoughtful public and private partnerships can shape vibrant, livable neighbourhoods,” Moran said.

Located adjacent to Rhodes railway station, stage one of Billbergia’s Rhodes Central Masterplan was completed in 2021 and included the 13,000 m2 Rhodes Central Shopping Centre, with convenience retail, a Woolworths supermarket, medical facilities and the Bamboo Lane dining precinct.

Other previous projects include the 1.2 ha Phoenix Park in Rhodes, the $63 million Bennelong Bridge, the popular Baylink Shuttle service, the 3500 m2 Wentworth Point Community Centre and Library, and the Wentworth Point Pop-Up Town Square.

Billbergia’s ongoing focus on placemaking and social infrastructure also includes the $8.4 million delivery of a library at its mixed-tenure development, Arncliffe Central, in Sydney’s south. There is the potential for 75% of Arncliffe Central’s dwellings to be dedicated to social, affordable and essential worker rental housing, along with 3400 m2 allocated to childcare, convenience retail and cafes, and a 4000 m2 park with play space for both residents and the broader community.

Top image caption: The Rhodes Recreation Centre location with two planned residential towers, Peake and Oasis. Image supplied.

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