Advanced Recycling: The future of plastic resource management?

As global plastic consumption rises, so does the need for effective recycling solutions. Traditional mechanical recycling has long been the standard, but its limitations highlight the need for alternative approaches.

Advanced recycling, also known as chemical recycling, is emerging as a promising solution. But how does it compare to mechanical recycling, and what role can it play in a sustainable future?

Traditional vs. advanced recycling

Mechanical recycling: The standard approach 

Most plastics are recycled mechanically through processes like washing, grinding, and remelting. While effective for certain plastics, this method struggles with mixed, contaminated, or degraded materials.

Advanced recycling: A step further 

Advanced recycling breaks plastics down at a molecular level, reverting them to raw materials for new plastic products. Techniques include:

• Pyrolysis – Converts plastics into oil or gas
• Solvolysis – Uses solvents to break down polymers
• Gasification – Converts plastic waste into syngas for energy or new materials

The challenges of mechanical plastic recycling

Mechanical recycling faces several obstacles:

• Contaminated or mixed plastics are difficult to recycle efficiently.
• Quality degradation occurs with repeated recycling, making plastics unsuitable for high-performance applications like food or medical packaging.
• Significant plastic waste still ends up in landfill, even in developed countries.

Can advanced recycling solve these issues?

Advanced recycling offers potential solutions by breaking plastics down into their chemical building blocks. However, it comes with challenges:

• High energy consumption – The process requires significant energy inputs, making it costly and less sustainable.
• Material losses – Yield losses mean less plastic is recovered than initially processed.
• Expensive to scale – Moving from pilot projects to full-scale operations has proven difficult.
• Some outputs are used as fuel – Converting plastic to fuel is not classified as recycling under most regulations.

Regulatory challenges and the Mass Balance Approach

Tracking recycled content

One of the main concerns with advanced recycling is the difficulty in tracking post-consumer recycled material content. Since chemically recycled plastics are virtually indistinguishable from virgin plastics, governments face logistical challenges in setting and enforcing recycling targets.

The Plastic Packaging Tax (PPT) in the UK

The UK’s PPT taxes packaging with under 30% recycled plastic. However, because chemically recycled plastics are mixed with virgin materials during manufacturing, measuring true recycled content is complex.

To address this, the UK government is proposing to permit the use of a Mass Balance Approach to calculate recycled content in chemically recycled plastic for PPT purposes. While the rules are not yet finalised, this method would allow businesses to allocate recycled content within their production processes, even when recycled and virgin materials are combined. This proposal aims to support the use of and investment in advanced chemical recycling technologies.

The role of advanced recycling in a Circular Economy

While not a silver bullet, advanced recycling can complement mechanical recycling to improve plastic waste management. If scaled effectively, it could:

• Process hard-to-recycle plastics
• Produce high-quality recycled plastic for food and medical packaging
• Reduce reliance on fossil-based virgin plastics

However, challenges remain in ensuring its economic viability, environmental impact, and regulatory acceptance. With continued innovation, investment, and policy support, advanced recycling could become an important part of the future of plastic sustainability.

Stay ahead of regulatory changes with Valpak

As the plastic recycling landscape evolves, businesses must stay informed about regulations like the Plastic Packaging Tax and their implications.

We offer expert compliance support to help businesses navigate these changes and implement sustainable packaging strategies.

Get in touch today to ensure your business stays compliant while contributing to a more circular economy.