CEFLEX and AEPW launch modular flexible plastic recycling tech to boost material value

01 Nov 2022 --- CEFLEX and the Alliance to End Plastic Waste (AEPW) are devising a commercial-scale recycling solution to address hard-to-recycle household flexible plastic waste. The system, branded ValueFlex, aims to streamline recycling processes for optimal economic efficiency.

The recycling model is based on a concept developed by CEFLEX that integrates sorting with processing in a modular and flexible approach to maximize value from flexible plastic packaging waste. The model has gone through multiple semi-industrial trials to achieve its current results.  

Support from consultants Roland Berger and HTP Engineering is now allowing CEFLEX and AEPW to move to the next phase of development – to demonstrate the solution commercially. 

“The ValueFlex concept has potential to support a circular economy for plastic waste by enabling the recycling of household flexible packaging waste at scale and fulfilling the burgeoning demand for high-quality post-consumer recyclate,” says Nicholas Kolesch, vice president of projects for AEPW. 

CEFLEX and the AEPW create a recycling solution for flexible plastics from household waste. The problem with flexibles 
Flexible plastics are one of the fastest-growing plastic packaging categories, yet their recycling rates remain very low. The leading cause can be attributed to the disarrayed recycling processes designed for the materials. 

“Flexible plastic packaging is one of the more challenging types of material to process and recycle, and there are urgent calls to accelerate solutions in this space,” says Kolesch. 

Other mechanical recycling solutions face challenges due to the lightweight, complex, and often food-contaminated packaging. These materials, or those with food particles on them, are harder to sort through and reuse to a maximized potential. 

Current solutions are generally limited to processing material recovered through a segregated collection of plastic bags and films used for product delivery in retail and commercial supply chains. 

“By improving the value and flexibility of sorting and recycling processes for polyolefin-based flexible packaging, we can support market demand for high-quality post-consumer recyclates from mechanical recycling and feedstocks for chemical recycling,” says Martyn Tickner, chief advisor for circular solutions at AEPW.

The companies report that countries without adequate waste management infrastructure for flexible plastic packaging produce a disproportionate amount of environmental waste.

Commercializing
To achieve the next phase of building their solution on a commercial scale, the AEPW and CEFLEX are investing investors to partner in developing a first-generation ValueFlex facility with a 50,000 metric ton annual processing capacity. 

“We are launching a call for expressions of interest for investors and partners to build and operate a first-generation commercial-scale ValueFlex plant. Together, the project partners will work with successful bidders providing expertise and relevant support,” says Dana Mosora, workstream consultant at CEFLEX.

The plant will be based in Europe and aims to be operational by 2025. Flexible plastics have low recycling rates despite being one of the highest manufactured plastics. 

According to the pre-feasibility study conducted by Roland Berger, the solution will be a crucial enabler in meeting market demand for post-consumer recyclates from mechanical recycling and providing fit-for-purpose feedstocks for chemical recycling. 

The study demonstrates a positive business case expected to catalyze further investment in sorting and recycling solutions for flexible packaging. The first-generation commercial implementation will provide a blueprint for replication.

Other flexible plastic recycling 
A few months ago, Fiberight announced a three-year £10 million (US$11.5 million) project to set up and run a commercial-scale demonstration plant for recycling mixed plastic waste in the UK.

At the same time, UK Research and Innovation and WRAP established a £1.2 million (US$1.4 million) project to assist six initiatives in Chile, India, South Africa, and Kenya targeted at solving difficult-to-recycle plastics, growing reusable packaging and introducing innovative business models in each respective country. 

Meanwhile, UK councils Cheltenham and South Gloucestershire are trialing curbside collections for flexible plastic packaging under the Flexible Plastic Fund (FPF) FlexCollect project. 

By Sabine Waldeck