Chemical innovation supports growing rPET demand
The growth in rPET usage is driven by a heady combination of legislation and consumer demand. The global rPET market was valued at USD 13159.36 m in 2022 and is expected to see a nearly 7% CAGR, bringing it to USD 19736.88 m by 2028. This, together with the recent study that shows 49% of consumers ‘feel better when they buy products with recycled packaging’, helps to explain why the upward trend for rPET usage shows no sign of slowing down.
European Commission legislation on the requirements for recycled plastic materials for food contact is defined in EU 2022/1616. The aim of this regulation is to increase the use of recycled materials, which of course is influencing the demand for rPET for converters and packaging manufacturers, particularly in the food and beverage industries. The requirements from the EU state that 100% of plastic packaging must be recyclable by 2029, including PET packaging in separate collections, broken down into 77% by 2025 and 90% by 2030. Furthermore, PET packaging must contain 25% post-consumer recycled plastic content from 2025.
However, the one potential pitfall is the unstable availability of rPET. Just because consumers want it and legislation says we must use it, doesn’t mean the industry can always get it in huge volumes. The challenge of a strong demand for rPET is showing in a lack of availability, with reliability of supply proving difficult for converters, producers and brands alike. PET resin and polyols producer Neo Group, founded in Lithuania in 2004, is proudly addressing this supply reliability issue while helping to close the loop for a circular economy. Its patented process, developed in-house by skilled chemical technologists, has created Neo PET Cycle.
Food grade rPET availability
Neo PET Cycle is a PET resin which includes up to 30% of rPET integrated directly into the virgin PET, so converters can use one product instead of two, while still meeting legislative requirements. Justina Volcek, PET Purchase Manager at Retal Group, explains, “They created Neo PET Cycle using a type of gentle glycolysis process and the result is a food contact grade resin that’s available at industrial volumes. With the partial replacement of fossil-based raw materials with liquified and purified rPET flakes, Neo PET Cycle supports Retal in meeting our environmental goals, as well as enabling our customers – the global brand owners of food and beverage products – to stay in line with both the EU legislation and the wishes of their consumers.”
These environmental advantages include a reduction of plastic pollution, lower CO2 emissions due to the lower carbon footprint of rPET as compared to virgin PET, while reducing dependence on oil reserves. The strict filtration technology used in the Neo PET Cycle production process purifies depolymerised PET flakes from contaminants, ensuring a stable colour, intrinsic viscosity and melting point, stated Retal. With Neo Group a sister company to the multinational plastic packaging producer Retal, specialises in preforms, closures and films for the food and beverage industry, the family connection allows for a preferred supply of Neo PET Cycle, helping to overcome the challenges of rPET supply for its customers.
The production process of Neo PET Cycle is based on a depolymerisation process using feedstock from postconsumer PET food packaging collections. Volcek explains, “The production consists of two raw material streams: standard raw materials and rPET flakes; Neo Group’s patented technology is a glycolysis process, chosen because it is the most efficient form of non-catalysed depolymerisation. Additionally, in Neo Group, they have a long experience in glycolysis processes producing their second product – aromatic polyester polyols – since 2011.” The technology and quality management system allow integration of flakes directly before the polymerisation stage of PET resin production, which enables part replacement of raw materials without affecting food contact approvals from state authorities for the final product. A senior Neo Group representative concludes, “We can keep control over the consistent product quality in the spherical shape of the resins, just as we can with our standard virgin Neo PET, which means that there’s no need for any changes in converters’, like Retal’s, processes. Neo PET Cycle allows customers to meet environmental legislation without any additional hassle.”
