What is Post Consumer Resin (PCR) Plastic? PCR's Pros and Cons ...

Post Consumer Resin (PCR) Plastic? PCR's Pros & Cons for Packaging

In today's environmentally conscious world, sustainability has become a significant focus across various industries. One solution gaining momentum is the use of Post-Consumer Recycled (PCR) plastic in packaging. PCR plastic, as its name suggests, is made from recycled materials, specifically consumer waste like plastic bottles and containers. 

EcoPlas supply professional and honest service.

By embracing PCR plastic, businesses can significantly reduce their reliance on fossil fuels and raw materials in production, minimizing their environmental impact and footprint. 

What are PCR resins?

What does PCR stand for? PCR stands for Post-Consumer Recycled material or Post-Consumer Resin. These are recycled plastics referred to as rPET (Recycled Polyethylene Terephthalate), rPP (Recycled Polypropylene Plastic) and rHDPE (Recycled High-Density Polythene).

The Journey of Post-Consumer Resin: How It’s Made 

To create PCR, recyclers start by gathering used plastic items like bottles, bags, and trays. These materials come from a variety of sources, including curbside recycling programs and ocean-bound plastics collected near waterways. 

Once collected, the plastics are sorted by type (PET, HDPE, PP), thoroughly cleaned, and processed. Most often, this involves grinding the plastics into flakes, melting them down, and forming them into small resin pellets. These pellets are then distributed to manufacturers who turn them into new containers and packaging. 

There’s also a process called chemical recycling, which breaks down plastics into their raw components using chemicals and high heat. While it produces high-quality results, it’s much more expensive and less common than traditional recycling. Regardless of the method, the goal is to produce clean, high-quality resin pellets while filtering out contaminants that could affect the color, strength, or usability of the final product. 

What is PCR Plastic Used For?

PCR plastic finds application in a wide range of industries and products. It is commonly used in the manufacturing of packaging materials such as bottles, jars, and containers for personal care items, cleaning supplies, food, beverages, and more. 

What is Virgin Resin?

Virgin resin refers to plastic made from new, non-recycled materials. Unlike PCR material, which utilizes post-consumer waste sourced from recycling programs and recycling facilities, virgin resin relies on raw materials derived from fossil fuels. It is commonly used in various industries and packaging applications, offering a wide range of physical properties and customization options. While virgin resin has its place in packaging, the rising popularity of PCR plastic demonstrates the increasing demand for sustainable alternatives in today's plastic materials market.

TircorBraun teamed up with Project Clean to create a 100% PCR bottles and containers for their product line.

Quality and Strength of PCR Packaging 

The good news? PCR packaging is just as durable as packaging made from virgin plastics. Whether it’s food-safe or non-food-safe, PCR retains the same strength, flexibility, and reliability as its non-recycled counterparts. This makes it a practical choice for everything from beverage bottles to household containers. 

However, PCR does have one visual quirk: containers made from 100% recycled material often have a gray or yellow tint. While this doesn’t affect performance or safety, it’s something to keep in mind if appearance is key to your packaging design. Mixing virgin resin with PCR can reduce this tint, creating a cleaner look while still incorporating recycled materials. 

Advantages of PCR Packaging

Using PCR plastic in packaging offers several advantages, contributing to both environmental sustainability and brand reputation. Some key benefits include:

Reduced Carbon Footprint: By utilizing post-consumer waste, PCR plastic reduces the consumption of fossil fuels and energy required in the production of new plastic, resulting in lower greenhouse gas emissions.

Resource Conservation: PCR plastic reduces the demand for virgin resin, conserving valuable natural resources such as petroleum and natural gas.

Waste Minimization: Incorporating PCR plastic into packaging promotes the circular economy by diverting plastic waste from landfills, fully embracing the recycling process and extending the useful life of materials.

Consumer Appeal: As eco-consciousness grows, consumers are increasingly favoring brands that demonstrate their commitment to sustainability. Using PCR packaging allows businesses to align with consumer values and strengthen their brand image.

Is PCR Packaging Worth the Cost? 

Using PCR in packaging does tend to cost more than virgin resin due to factors like supply and demand, recycling processes, and material availability. However, this higher price point comes with significant benefits: 

Brand Appeal: Customers are increasingly willing to pay more for products with sustainable packaging. An additional survey from Accenture confirms this, with 72% of respondents saying they would pay more for products with packaging that is reusable or recyclable. 

Regulatory Compliance: States like California are enforcing minimum PCR content requirements, making it a necessity for many brands. 

Positive Impact: Choosing PCR helps divert plastics from landfills and waterways, supporting broader environmental goals. 

While the upfront cost may be higher, the long-term benefits, like brand loyalty and staying ahead of regulations, often make it a worthwhile investment. 

Things to Consider Before Using PCR Packaging

While PCR plastic presents numerous advantages, it is important to consider specific factors before transitioning from virgin resin to PCR packaging. Some considerations include:

Regulatory Compliance: Ensure compliance with regional regulations and certifications related to the use of PCR plastic, as these may vary.

Quality and Performance: Evaluate PCR plastic's physical properties, such as clarity, strength, and barrier properties, to ensure they meet the specific requirements of your product.

Supply and Availability: Assess the availability of PCR plastic in sufficient quantities to meet your packaging needs, considering potential fluctuations in supply chains.

Cost Considerations: Understand the potential cost implications associated with PCR plastic, including any additional processing or sourcing expenses.

The rise of PCR plastic in packaging signifies a significant step towards a more sustainable and environmentally friendly future. By harnessing the advantages of PCR plastic and considering important factors, businesses can make informed decisions to reduce their environmental footprint while meeting consumer demands. Embrace the power of PCR plastic and join the journey toward a greener, more responsible approach to eco friendly packaging.

What You Need to Know About Post-Consumer Recycled (PCR) Packaging 

Both savvy shoppers and consumer packaged goods companies are placing more emphasis on sustainability, reducing waste, and using less energy. As a brand owner, your sustainability goals are more important now than ever, as consumers begin seeking out brands focused on the environment.  

When it comes to packaging, it’s no surprise that brands are looking for eco-friendly packaging. While recyclable or compostable packaging are the two most common types of sustainable packaging, there is a third choice gaining traction on the shelf – post consumer recycled (PCR) packaging.

What are Post-Consumer Recycled (PCR) Plastics? 

Post-consumer recycled content, often referred to as PCR, is material that is made from the items that consumers recycle every day, like aluminum, cardboard boxes, paper, and plastic bottles. These materials are typically collected by local recycling programs and shipped to recycling facilities to be sorted into bales, based on the material. The bales are then purchased and melted (or ground) into small pellets and molded into new items. The new PCR plastic material can then be used for a variety of finished products, including packaging.

How is PCR Packaging Different from Recyclable and Compostable Packaging?

Though PCR, recyclable, and compostable packaging are all sustainable packaging options, they each differ in the way that they are processed and what they can offer consumers. 

PCR packaging is manufactured with film that is made from recycled materials. In general, PCR packaging, such as post consumer recycled plastic, cannot be recycled again since it’s already made from recycled materials. This allows brands to fulfill their sustainability goals, without relying on the consumer to recycle or compost the package after use. 

A package is deemed recyclable when the materials can be processed and used again.  Once the package enters the recycling stream, it is broken down into raw materials and sold to manufacturers. One potential downside of recyclable packaging is that the benefits are dependent on the consumer actually recycling the package, and knowing where to recycle the package.

Lastly, compostable packaging is packaging that breaks down completely in a compost site and leaves no toxic residue. In order for a plastic to be called compostable, it must biodegrade, or break down into carbon dioxide, water, or biomass at the same rate as cellulose (paper).  One potential downside of compostable packaging is that not all consumers have access to industrial composting facilities. 

The Benefits of PCR Packaging 

Post-consumer resin offers a lower carbon footprint compared to virgin materials. Use of PCR diverts waste from landfills, decreases the consumption of virgin raw materials, and reduces emissions while promoting the circular economy.

While all eco-friendly packaging options are a step in the right direction for brands looking to be more sustainable, PCR packaging, in particular, has some benefits that are worth discussing. 

In general, PCR films are a great packaging option for brands looking for eco-friendly flexible packaging, and can be developed into stand up pouches, lay flat pouches, and rollstock. These films can be used in most industries including confection, coffee, baked goods, snacks, pharmaceuticals, herbal remedies, pet treats, and sports nutrition.

PCR packaging also matches the quality of regular flexible packaging. PCR film can offer the same level of protection, barrier performance, and strength as regular plastic film. You can rest assured knowing that PCR film will still block light, oxygen, and other gases from penetrating the package layer and getting into your product. 

Lastly, and quite possibly the most obvious benefit, is that using PCR material can help your company reduce its carbon footprint, lessen its impact on landfills, and meet its overall sustainability goals.

The best part? PCR packaging is a great option for brands who want to offer a sustainable solution for consumers, with no requirements or actions needed on the consumer end, unlike recyclable and compostable packaging. 

What exactly is PCR plastic… and why do we use it?

Packaging. It gets a bad (w)rap… and deservedly so. Particularly single-use plastic packaging.

Plastic packaging in the UK accounts for nearly 70% of our plastic waste, covering our food, containing our drinks, encasing the stuff we buy for our homes… it’s something all brands MUST consider when they decide how to package and protect their products.

Back in , we launched our smol laundry capsules in 100% recycled plastic packs. It was a step-up from the brand new plastic that the main brands were using but even then we knew we could do better. We worked tirelessly to change this and introduced our world-first child-impeding, home-compostable cardboard laundry packs just 2 years later.

Ditching the plastic felt good.

But the cold truth remains that every type of packaging still demands resources… energy, raw materials, labour and transportation. In fact the only true eco-packaging is NO packaging. And for many products that is simply not an option.

You’ll notice for some of our products we still use 100% recycled plastic. This is what’s called Post-Consumer Resin plastic - or PCR plastic, and we’re often asked what exactly is it? How is it made? And what makes it better than virgin plastics?

So let’s take a look…

Are you interested in learning more about Post Consumer Recycled Resin? Contact us today to secure an expert consultation!

What is PCR plastic made from?

It consists of recycled plastics such as:

PET (used in water bottles)

PP or Polypropylene Plastic (used in lids of sauce bottles for example)

HDPE or High-Density Polythene (used in cleaning product bottles)

It’s all just basically the plastic from your home that pours into the waste system via your kerbside collection.

How is it made?
 

The plastics are sorted based on their type of material

Then either melted, shredded or ground into pellets or fine granules

Next the pellets are melted down and remoulded

This creates new PCR plastic products, without any additional brand new plastic material

What is so good about PCR plastic?

At first glance, PCR plastic is simply taking a waste product, turning it into something useful once again and keeping it OUT of landfill, OUT of the oceans or preventing it from being incinerated and releasing its carbon that way. It is taking something that has already been manufactured and extending its useful life. The additional benefits of not needing brand new fossil resources are of course important and a major attraction to us here at smol.

PCR plastic is also created using far less water and less energy than virgin plastic and generates fewer carbon emissions than manufacturing its equivalent out of brand new plastic.

One report* took a detailed look at all lifecycle impacts involved in making a product from PCR plastic compared to the same product being made from virgin plastic.

It concluded that using PCR plastic reduced energy consumption by 79% for PET, and by 88% for HDPE and PP. It also reduced all greenhouse gas emissions during production.

AND what’s really great is that it is a durable material. This is additionally important to us here at smol when selecting a material for our refillable bottles. We want these to live on indefinitely, being refilled time and time again so they need to be sturdy and long-lasting.

Refilling and reusing a plastic bottle each time means our customer saves 41.4 grams of carbon dioxide. Over the course of a year, two years, five years… you can see how the savings add up when you refill your bottle and don’t buy new.

Are there any disadvantages to PCR plastic?

Unfortunately, as a material, PCR plastic does have limitations. For example, it may not be used in the food industry as there are issues around food safety. It is not suitable to use as a packaging material for fruit or vegetables. Which is a shame because such a high percentage of plastic waste comes from the packaging we use in the food industry.

PCR plastic can also not be manufactured in any colour so that might be off-putting for some brands. It’s hard to make a proper transparent pot for example because PCR plastic is just not fully transparent. It is made from different types of waste plastic from multiple different original items which makes it hard to create a consistent uniform look.
 

Can PCR plastic be recycled itself?

Depending on how the PCR plastic is used it can actually be recycled again after use which makes it a circular material. Some studies show you can safely recycle PCR plastic between 7 and 9 times before the fibres have degraded to an extent that makes them unsuitable for further use.

Of course much better to refill rather than recycle but at least the recycling option is there.

So will we always use PCR plastic in our range?

Finding viable alternatives to plastic packaging is a constant and ongoing mission here at smol so we hope one day to end our use of recycled plastic. In the meantime it’s an improvement on the status-quo within the cleaning industry and the millions of brand new plastic packs spewing out from the big brands every year.

Pledges by the likes of Unilever and Procter & Gamble to cut their use of single-use plastic in 5 or 10 years and slightly increase their use of PCR plastic is pitiful. They have put profit over planet for many decades. We hope that pressure from small independents like smol and growing awareness from the population will force them finally to step up.

PCR plastic is not perfect.

To make measurable change we don’t need a handful of people doing zero waste perfectly. We need millions of people doing it imperfectly.

A huge number of our customers take advantage of our Rinse, Return and Lend a Hand scheme whereby for every 4 empty bottles sent back to us to reuse, we'll donate 1 pack of laundry capsules to The Hygiene Bank, who work tirelessly to end hygiene poverty for the most vulnerable nationwide.⁠ This means our bottles can be used again and again which of course is great news for the environment, while supporting an amazing cause.

And whilst we’re not sure any packaging is perfect, in our opinion refillable PCR improves on the billions of brand new plastic packs that are used once and thrown away.

FAQs About PCR

Is PCR safe for food packaging?

Yes, when processed correctly, PCR can meet FDA standards for food safety. Always confirm that the material meets your industry’s requirements. 

How does PCR compare to virgin resin in cost and durability?

While PCR is generally more expensive than virgin resin, it offers comparable strength and reliability, making it an excellent alternative for sustainable packaging. 

What industries use PCR packaging the most?

Industries like food and beverage, personal care, and household goods are leading the way in adopting PCR packaging.