Sustainability Through Plastics

The plastics industry makes a major contribution to the achievement of a sustainable development strategy. It is extremely important to recognise that the plastics industry contributes to sustainability in manufacture, in use and in resource minimisation of plastics and also at their end of life.

Sustainable Manufacture

• Plastics use only 4% of the world’s oil as feedstock compared to 86% used for heating and transport. Most of this is recoverable via energy recovery ie plastics only ‘borrow’ energy during their life time and this can be recovered in the form of heat, which can then be converted to electricity.
• The energy to manufacture plastics from raw materials compares favourably with for eg metal ore smelting and glass manufacture. Furthermore, the plastics industry uses clean technology minimising emissions.
• Conversion energy (energy consumed during the processing of plastic resin into useful products) is also low compared to metal and glass processing since lower process temperatures are required.
• Most manufacturers process their own scrap material in-house so that a large quantity of plastics manufacturing scrap never enters the waste stream.

Plastics thus present an example of eco-efficiency.

Minimisation of Resources

• The plastics industry’s record on lightweighting is excellent. As new technologies and new designs are developed, less and less material is needed for the same effect and purpose. For example:
  • In 1970 the average plastics yoghurt pot weighed 11.8g, but in 1990 only 5g was needed to package the same amount.
  • Similarly, a plastics detergent bottle weighed 300g, and by 1985 this had been reduced to just 100g.
  • For film the use of less and less material for the same use has been very dramatic - from 180µm 15 years ago to 80µm thick material now.
  • Sacks have halved in thickness (from 300 µm to 165 µm) and carrier bags are now 15 µm thick (from 45 µm 10 years ago).
  • The average weight of stretch wrap for pallet wrap is now 350 g replacing the 1400g of shrink wrap used ten years ago.
• because of the light weight of plastics transport costs and emissions are reduced for example, for yoghurt packed in glass pots 36% of the weight is packaging, for plastic packaging only 3.5%. This means that 3 trucks are needed to transport yoghurt packed in glass, and only 2 for the case of plastic pots.

Overall 10m litres extra petrol or diesel would be needed and 22m kg of CO2 extra would be emitted if all plastics packaging was to be replaced by alternatives.

Plastics present an excellent example of resource efficiency.

Plastics in use by market sectors and some examples of energy savings

• Packaging - If packaging without plastics is considered, then the waste doubles, energy consumption for production doubles, weight quadruples and cost doubles.
• Plastics packaging saves waste especially food. In developing countries there is 45-50% food spoilage, but only 2% in west.
• The light weight of plastics means they are used for aircraft crockery and drinks bottles and this light weight weight saves in fuel consumption.
• Automotive - plastics in cars are a tremendous example of resource efficiency. Obviously the use of lighter materials will reduce fuel consumption and thus emissions. Increased safety is also one of the major benefits. Plastics provide major environmental benefits throughout the lifetime of a car. Component integration, low weight, low energy moulding processes, long life and reduced maintenance needs all contribute positively to reduction of emissions, particularly through reduction in carbon dioxide emissions since less fuel is needed. Whilst from 1974-1988 there was a growth in plastics from 3% to 11% of total weight of a car there was a commensurate 14% decrease in petrol consumption over the same period. In the average car 200-300 kilogrammes of conventional material has been replaced by 100 kilogrammes of plastic and because of this fuel consumption has been reduced by 750 litres over average lifespan of a vehicle. The percentage of the total weight has stayed fairly static because the overall weight of cars has increased because of increased demands for added safety features and consumer comfort. Without the use of plastics this weight increase would have been substantially higher.
• The use of plastics GRP panels in Swiss trains has led to a 25% reduction in weight.
• The use of anti-corrosion plastics coatings extends vehicle life.
• Construction - the use of EPS, PU or melamine formaldehyde foam insulation save energy. 1kg oil used to make EPS will save the equivalent of 75 kg oil for heating over 25 years.
• PVC-U windows save on manufacturing costs, and also on maintenance and replacement.
• Plastics pipes use less energy to produce than concrete or iron and since lightweight they save on transport costs and emissions in the building industry.
• Electrical - plastics helped facilitate the information technology revolution with all its implications for business efficiency in the EU, and, as a technological leap forward, its potential positive consequences for standards of living and the opportunity to provide for the more effective targeting and use of resources Plastics are used in electrical applications because they are insulants, both thermal and electrical eg refrigerator insulation saves on running costs.
• Lightweight - alternative materials would be heavier, and probably be less energy efficient to manufacture.
• Durable.
• Able to present freedom of design.
• Energy efficient to produce.
• Recyclable.

End of life plastics

Where suitable ie large arisings, clean and of one type, plastics recycling leads to resource conservation. In 2001 more then 290,000 tonnes of post use plastic were recycled. Examples are:

• Polyethylene film reclaimed from applications such as pallet shrink wrap and agricultural silage wrap.
• Polypropylene from vehicle battery cases, bottle crates and transit trays.
• Polyethylene from industrial containers, transit boxes and milk bottle crates.
• PVC from stripped electrical cable.
• Polystyrene from vending cups.
• Expanded polystyrene from transit packaging.
• ABS from telephone handsets and machine housings.
• Acrylic from illuminated signs.
• Mixed plastics directly converted into new products such as extrusion moulded posts and building boards for agricultural applications
• Bottles from domestic sources.
• Feedstock recycling gives a highly efficient way of recovering the plastics materials at end of life. The UK is a leader in this technology.
• Waste plastics can also be used to provide chemical reduction in blast furnaces.
• Waste to energy is also a highly efficient way of recovering the inherent energy of plastics. 1 yoghurt pot contains enough energy to light 60 watts for 1 hr. One carrier bag if burned can provide enough energy to light a 60 watt bulb for 10 minutes.

The BPF pioneered the recovery and recycling infrastructure for plastics, in particular by funding a 3 year project at Sheffield into collection schemes and a project with Greater Manchester Waste Disposal Authority to look into mechanical recovery and sorting methods for plastics.

The BPF has initiated and administered a Recycling Council, largely made up of plastics recyclers and with the main aim of encouraging greater recovery and recycling of plastics. The BPF was a founder member and supporter of Valuplast, the plastics industry organisation set up to facilitate implementation of the Producer Responsibility Regulations for plastics packaging waste.

The BPF has been an active participant in the bench marking, energy efficiency and environmental technology best practice programmes and to encourage even greater awareness amongst our members of the importance of environmental management systems.

The BPF has actively encouraged best practice in terms of accident prevention and health and safety, through the work of its Industrial Health and Safety Committee and in promoting the concept of ‘Good Health is Good Business’.

For further information Email the BPF on: bpf@bpf.co.uk