New study highlights capacity gaps in the recycling of PET trays

Transparent PET trays and plastic waste on a conveyor belt at a recycling plant

The Forum Rezyklat has published a study on recycling capacities, sorting and design for recycling.
 
The study, commissioned by the Forum Rezyklat in collaboration with the IK Industrievereinigung Kunststoffverpackungen e.V., was carried out by the cyclos – HTP Institute, the GVM Gesellschaft für Verpackungsmarktforschung and the Fraunhofer Institute for Building Physics IBP. It concludes that existing recycling capacities would need to be significantly expanded in order to meet the requirements of the EU Packaging Regulation (PPWR) for recycling on an industrial scale. This is because, according to the definition of ‘packaging waste recycled on a large scale’ (‘Recycling at Scale’) in Article 3(39) of the PPWR, it must be ensured that, from 2035, at least 55 per cent of individual packaging categories are recycled. If, therefore, there are no comprehensive sorting and recycling facilities for a particular type of packaging across large parts of Europe, recycling ‘at scale’ is not possible and, as a result, the packaging may no longer be placed on the market. According to Forum Rezyklat, the current study analyses the market volume of PET trays, existing collection, sorting and recycling structures, and the prerequisites for ‘tray-to-tray’ recycling in accordance with the PPWR. It concludes that scaling up in line with the PPWR will require adjustments across the entire value chain. However, according to the study, a closed-loop system for polyethylene terephthalate (PET) trays is, in principle, feasible. Technologies for sorting this packaging and returning it to the material cycle are available, but are not currently in widespread use.
 
According to the authors, around 18 per cent of PET trays in Germany are currently processed into new recycled material, meaning they have a significantly lower material recycling rate compared with other plastic packaging. According to the study, Germany has the highest consumption of PET trays in the EU, at 144,000 tonnes per year. According to the study, a total of around 824,000 tonnes of such PET packaging is generated annually across the EU-27. The study estimates that the current recycling capacity for PET trays stands at approximately 235,000 to 250,000 tonnes. A projected shortfall of around 454,000 tonnes is forecast for 2035. According to the authors, in order to achieve recycling on an industrial scale in line with the PPWR from 2035 onwards, recycling input capacities of around 697,000 tonnes per year would then be required across Europe. This volume corresponds to the capacity of around six to eight large-scale plants. The study identifies barriers to the expansion of recycling, including high investment costs, current price differences between virgin PET and recycled PET, and a lack of long-term off-take agreements.
 
Lisa Marie Ruffert, Circular Consultant at BellandVision and Head of the PET Trays work package at Forum Rezyklat, explains: “The study provides a robust overview that highlights the current challenges and clearly identifies gaps. It is now crucial to tackle the identified areas for action collaboratively along the value chain.”
 
According to its own statements, Forum Rezyklat has already commissioned the second phase of the study. This is intended to develop technology scenarios for the years 2030 and 2040, taking into account the PPWR’s requirements for industrial-scale recycling, and to provide material balances and reliable cost estimates for this purpose.
 
Further information: The full publication „PET Tray Recycling: Status quo, Challenges and Future Scenarios Phase 1“ is available to download free of charge from the Forum Rezyklat website.
 
Sources:

Go back