Recycled content in UK dairy caps with a minimum 30%
In line with incoming packaging tax regulation in the UK to be introduced in April 2022, Paccor’s production team in Mansfield, UK, are now offering caps with a minimum 30% rHDPE (recycled high density polyethylene). This created a challenge due to the different nature of PCR material compared to virgin polymer but was enabled by the company’s CCM (Continuous Compression Moulding) technology.
In the UK, about 79% of the HDPE bottles collected are recycled, of which a high percentage are milk bottles. On average, about 15% of HDPE milk bottles in the UK contain up to 30% recycled rHDPE material. Technical advances in the manufacture of these containers have also led to the use of less material, resulting in a lower weight for the same bottle size.
“The rHDPE produced in the UK is under pressure due to availability and demand,” underlines Andreas Schuette, CEO of Paccor. “All UK bottle manufacturers are aiming for a minimum share of 30% rHDPE content to avoid plastic tax. However, thanks to our long-term partnership with the supplier, Paccor has now managed to ensure sufficient material availability and increase the content of the caps up to 40%,” he says.
The company’s procurement team sourced rHDPE material and the site now produces approximately 45 million caps per week. The engineering and technical team tested various extrusion nozzle diameters and cutter holder profiles until a solution was found and trials with up to 40% inclusion rate were successful. Increased machine setup accuracy ensured consistent forming of the cap, with no compromises to customers filling process.
“This development reduces the volume of virgin HDPE used for our closure production by more than 1,000 tons per annum and provides estimated carbon footprint savings of 1.3kt CO2eq per year,” Andreas Schuette concludes.
