Enhancement in Post-Consumer Mechanical Recycling of Plastics: Role of Design for Recycling, Specifications, and Efficient Sorting of Packaging Material

Plastic packaging materials can play a significant role in turning the plastic industry towards a circular economy, owing to their large volumes and short product lifetimes. This study emphasizes the role and interaction of design for recycling (DfR), appropriate specifications, and efficient sorting. DfR is enhancing the recyclability of plastic packaging by selecting appropriate materials and designs, improving the quality of recyclates without compromising safety or the original requirement. A significant barrier to achieving a circular economy is the lack of comprehensive standards for recycled plastics. While some specifications exist, a more integrated and globally accepted standardization regime, similar to that in the aerospace industry, is necessary to ensure quality and consistency in recycled materials. The potential of advanced sorting technologies to improve sorting efficiency and feedstock quality is highlighted, significantly enhancing recovery yields and the quality of recyclates. Information-based tracking technologies, such as digital watermarks, offer substantial benefits in identifying and sorting materials with high granularity, improving sorting mechanisms, enhancing resource recovery, and providing valuable data for stakeholders across the plastic value chain. The implementation of information-based technologies can reduce production costs and environmental impacts, with exemplary calculations indicating a potential 30% reduction in the production cost of PP recyclate.