Circular economy for plastics: potentials and uncertainties considering technical and social aspects

The increasing plastic consumption and inadequate end-of-life solutions have led to significant pollution, prompting policymakers to act. In a circular economy, waste reduction is essential, but recycling must also replace landfilling and energy recovery. To achieve this, a holistic perspective is needed to identify challenges across the entire lifecycle. This research explores key questions like: Can packaging be fully recyclable? What role do labels play? And why are there no closed-loop applications for polypropylene (PP)? Additionally, the perceptions of consumers were examined to understand their often neglected view. This study analyzed various PP packaging through mechanical, thermal, and rheological testing, comparing them within each other and to virgin materials. Online surveys were used to gather consumer pereceptions. Findings revealed that while labels serve as crucial information carriers and display good mechanical stability, rheological and thermal analysis highlighted persistent challenges. Furthermore, toxic substances detected after processing indicate that label recycling must be approached with caution. Therefore, using 100% of the packaging for recycling is not yet possible, however, the efficient use of labels (around 2% of packaging) brings us closer to achieving this goal. PP faces additional obstacles due to its different grades and various decoration technologies, which hinder accurate sorting and closed-loop recycling. Inks, such as those found on labels, introduce harmful substances that affect the safety of the recycled material. Meanwhile, consumer perceptions of plastic remain largely negative, despite its crucial role in closing the recycling loop. Collaboration between all parties involved is essential for a successful transition. Inks need to be removed from the recycling stream through an easily removable label. In addition, standardization of PP grades and decoration methods would improve identification and sorting, resulting in larger quantities of high-quality recyclates. Clearer guidelines would also raise consumer confidence in recycling. A systemic shift is necessary—only through joint efforts can plastic packaging become a truly circular material.