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Plastic recycling
Plastic recycling
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Plastic recycling
Clockwise from top left:
  • Sorting plastic waste at a single-stream recycling centre
  • Baled colour-sorted used bottles
  • Recovered HDPE ready for recycling
  • A watering can made from recycled bottles

Plastic recycling is the processing of plastic waste into other products.[1][2][3] Recycling can reduce dependence on landfills, conserve resources and protect the environment from plastic pollution and greenhouse gas emissions.[4][5][6] Recycling rates lag behind those of other recoverable materials, such as aluminium, glass and paper. From the start of plastic production through to 2015, the world produced around 6.3 billion tonnes of plastic waste, only 9% of which has been recycled and only ~1% has been recycled more than once.[7] Of the remaining waste, 12% was incinerated and 79% was either sent to landfills or released into the environment as pollution.[7]

Almost all plastic is non-biodegradable and without recycling, spreads across the environment[8][9] where it causes plastic pollution. For example, as of 2015, approximately 8 million tonnes of waste plastic enters the oceans annually, damaging oceanic ecosystems and forming ocean garbage patches.[10]

Almost all recycling is mechanical and involves the melting and reforming of plastic into other items. This can cause polymer degradation at the molecular level, and requires that waste be sorted by colour and polymer type before processing, which is often complicated and expensive. Errors can lead to material with inconsistent properties, rendering it unappealing to industry.[11] Though filtration in mechanical recycling reduces microplastic release, even the most efficient filtration systems cannot prevent the release of microplastics into wastewater.[12][13]

In feedstock recycling, waste plastic is converted into its starting chemicals, which can then become fresh plastic. This involves higher energy and capital costs. Alternatively, plastic can be burned in place of fossil fuels in energy recovery facilities, or biochemically converted into other useful chemicals for industry.[14] In some countries, burning is the dominant form of plastic waste disposal, particularly where landfill diversion policies are in place.

Plastic recycling is low in the waste hierarchy, meaning that reduction and reuse are more favourable and long-term solutions for sustainability. It has been advocated since the early 1970s,[15] but due to economic and technical challenges, did not impact the management of plastic waste to any significant extent until the late 1980s.

History

[edit]

Although plastics were discovered before the 20th century, large-scale production was not realised until World War II. Nylon replaced silk in parachutes, while Perspex was a light-weight alternative to glass in aeroplanes. After the war these materials were commercialized. The plastic age began around 1950, part of the post-war economic boom.

Global environmental movements in the 1960s and 1970s led to the formation of environmental agencies in the US (EPA, 1970), EU (DG ENV, 1973) Australia (EPA, 1971) and Japan (JEA 1971). Environmental awareness put plastic waste under scrutiny.[15] The earliest effort to abate plastic pollution was arguably the 1973 and 1978 MARPOL agreements, whose Annex V banned dumping plastics in the oceans.

Industry lobbying

[edit]
Photograph of Girl Scouts picking up discarded trash in 1970.
Girl Scouts on a Keep America Beautiful cleanup in 1970. The Keep American Beautiful campaign was a greenwashing campaign by the plastics and other polluting industries founded in the 1970s to try to displace responsibility of plastic pollution and other disposable packing trash onto consumers as "littering".[16]

As regulations expanded, the plastics industry responded with lobbying to preserve their business interests. In the U.S., the 1970 Resource Recovery Act directed the nation towards recycling and energy recovery.[15] More than a thousand attempts to pass legislation to ban or tax packaging, including plastics, came by 1976.[17] The plastics industry responded by lobbying for plastic to be recycled. A $50 million per year campaign was run by organisations such as Keep America Beautiful with the message that plastic could and would be recycled,[18][19] as well as lobbying for the establishment of curbside recycling.[20]

However, plastic could not be economically recycled using the technology of the time. For example, an April 1973 report written by industry scientists stated that, "There is no recovery from obsolete products" and that, "A degradation of resin properties and performance occurs during the initial fabrication, through aging, and in any reclamation process." The report concluded that sorting the plastic is "infeasible". Contemporary scientific reports highlighted numerous technical barriers.[21][22][23][24][25]

Globally, plastic waste was almost entirely disposed of via landfill until the 1980s when rates of incineration increased. Although better technology was known,[26] these early incinerators often lacked advanced combustors or emission-control systems, leading to the release of dioxins and dioxin-like compounds.[27]

In the late 1980s plastic recycling began in earnest. In 1988 the U.S. Society of the Plastics Industry created the Council for Solid Waste Solutions as a trade association to promote the idea of plastic recycling to the public.[28] The association lobbied American municipalities to launch or expand plastic waste collection programmes and lobbied U.S. states to require the labelling of plastic containers and products with recycling symbols.[18][19]

The industry introduced resin identification codes in 1988, which provided a standard system for the identification of various polymer types at materials recovery facilities.

Global recycling trade

[edit]

Globalisation during the 1990s included the export of plastic waste from advanced economies to developing and middle-income ones, where it could be sorted and recycled less expensively. The annual trade in plastic waste increased rapidly from 1993 onwards as part of the global waste trade.[29]

Many governments count items as recycled if they have been exported for that purpose, regardless of the actual outcome. The practice has been labeled environmental dumping, as environmental laws and enforcement are generally weaker in less developed economies.[30][31] By 2016 about 14 Mt of plastic waste was exported, with China taking 7.35 Mt.[29] Much of this was low quality mixed plastic that ended up in landfills. However, recycled plastic is used extensively in manufacturing in China, and imported plastic waste was predominantly processed using low-technology processing. High-income countries such as Germany, Japan, the United Kingdom and the United States were the top exporters.[32]

In 2017, China began restricting waste plastics imports via Operation National Sword. Exporters eventually exported to other countries mostly in Southeast Asia, such as Vietnam and Malaysia, but also Turkey and India.[33][34] Indonesia, Malaysia, and Thailand reacted to illegal plastic waste imports by reinforcing border controls. Illegally imported containers were repatriated or refused entry. Consequently, plastic waste containers accumulated in ports.[32]

Given limited export options, attention turned to local solutions. Proposed extended producer responsibility would tax plastic producers to subsidise recyclers.[35]

In 2019, international trade in plastic waste became regulated under the Basel Convention. Under the convention, any Party can decide to prohibit imports of hazardous plastic waste and, since 1 January 2021, of some mixed plastic wastes. Parties to the convention are required to ensure environmentally sound management of their refuse either through alternative importers or by increasing capacity.[32]

The COVID-19 pandemic temporarily reduced trade in plastic waste, due in part to reduced activity at waste management facilities, shipping disruptions, and low oil prices that reduced the cost of virgin plastic and made recycling less profitable.[32]

European Union strategic developments

[edit]

The European Commission's "Action Plan" for a circular economy, adopted in December 2015, saw plastics as a strategic priority for developing circular economy actions. In 2017, the Commission further adopted a focus on plastic production and use, targeting the achievement of all plastic packaging being recyclable by 2030. The Commission then issued a strategic document in January 2018 which set out an "ambitious vision" and an opportunity for global action on plastic recycling.[11]

Production and recycling rates

[edit]
see caption
Global quantities of plastic produced and disposed of annually (1950–2015), showing the estimated amounts disposed of via landfill, recycling and incineration

The total amount of plastic ever produced worldwide, until 2015, is estimated to be 8.3 billion tonnes (Bt).[7] Approximately 6.3 Bt of this was discarded as waste, of which around 79% accumulated in landfills or the natural environment, 12% was incinerated, and 9% was recycled - only ~1% of all plastic has been recycled more than once.[7] More recently, as of 2017, still only 9% of the 9 Bt of plastic produced was recycled.[36][37]

By 2015 global production had reached some 381 million tonnes (Mt) per year.[7] The recycling rate that year was 19.5%, while 25.5% was incinerated and the remaining 55% disposed of, largely to landfill. These rates lag behind those of other recyclables, such as paper, metal and glass. Although the percentage of recycled or incinerated material is increasing each year, the tonnage of waste left-over also continues to rise. Production could reach ~800 Mt per year by 2040, although implementing all feasible interventions could reduce plastic pollution by 40% from 2016 rates.[38]

Recycling rates vary among types of plastic. Several types are in common use, each with distinct chemical and physical properties. This affects sorting and reprocessing costs; which affects the value and market size for recovered materials.[39] PET and HDPE have the highest recycling rates, whereas polystyrene and polyurethane are rarely recycled.[40]

One of the reasons for low levels of plastic recycling is weak demand, given the materials' poor/inconsistent properties.[11] The percentage of plastic that can be fully recycled, rather than downcycled or go to waste, can be increased when manufacturers minimise mixing of packaging materials and eliminate contaminants. The Association of Plastics Recyclers has issued a "Design Guide for Recyclability".[41]

The most commonly produced plastic consumer products include packaging made from LDPE (e.g. bags, containers, food packaging film), containers made from HDPE (e.g. milk bottles, shampoo bottles, ice cream tubs), and PET (e.g. bottles for water and other drinks). Together these products account for around 36% of plastic production. The use of plastics in building and construction, textiles, transportation and electrical equipment accounts for another substantial share of the plastics market.[42]

Regional data

[edit]

Plastic consumption differs among countries and communities, although it is found almost everywhere. As of 2022 North American countries (NAFTA) accounted for 21% of global plastic consumption, closely followed by China (20%) and Western Europe (18%). In North America and Europe per capita plastic consumption was 94 kg and 85 kg/capita/year, respectively. China reached 58 kg/capita/year.[42]

In 2012, 25.2 Mt of post-consumer plastic waste was collected in the European Union. Of this, more than 60% (15.6 Mt) was recovered and 40% (9.6 Mt) was disposed of as municipal solid waste (MSW). Of the 15.6 Mt of recovered plastic waste, about 6.6 Mt was recycled, while the remainder was likely used as refuse-derived fuel (RDF) or incinerated in MSW incinerators with energy recovery (about 9 Mt). Europe leads in plastics recycling, reusing about 26%.[43]

The recycling activities of the largest producers of plastic waste have the greatest effect on global averages. These are a mix of advanced economies and large developing nations. Some publish official statistics on their plastic recycling rates. Others may release partial data, usually limited to population centres. This makes it difficult to draw accurate comparisons, especially as the published recycling rates vary.

12 largest producers of plastic waste (+EU) and their recycling rates in 2010
Country Plastic waste per year (Mt)[44] Waste per person per day (Kg)[44] Recycled Incinerated (with energy recovery) Landfill (and incineration without energy recovery) Comments
China 59.08 0.12 - - - No official statistics
United States[45] 37.83 0.34 8% 14% 78% Source: EPA
EU total*[46] 24.7 0.15 24% 34% 42%
Germany[46] 14.48 0.48 33% 65% 2%
Brazil 11.85 0.17 - - - No official statistics
Japan[47] 7.99 0.17 27% 49% 24%
Pakistan 6.41 0.10 - - - No official statistics
Nigeria 5.96 0.10 12% 0% 88% Estimated values
Russia 5.84 0.11 6% 0% 94% World bank estimates (2013)[48]
Turkey 5.60 0.21 5% 0% 95% Estimated values
Egypt 5.46 0.18 - - - No official statistics
Indonesia 5.05 0.06 19% 0% 81% Estimated values
United Kingdom[46] 4.93 0.21 23% 8% 69%
Spain[46] 4.71 0.28 23% 17% 60%
France[46] 4.56 0.19 18% 40% 42%
India 4.49 0.01 42% 18% 40% Estimated values
Rest of World 60.76 - - - - No official statistics
World Total[7] 245.00 0.10 16% 22% 62%

* Although not formally a country, legislation affecting recycling is often made at the EU level

Identification codes

[edit]
See caption
Global plastic waste generation by polymer type. Colours indicate recyclability:
  • Blue is widely recycled.
  • Yellow is sometimes recycled.
  • Red is usually not recycled.

Many plastic items bear symbols identifying the type of polymer from which they are made. These resin identification codes (RIC), are used internationally.[49] They were developed in 1988 by the Society of the Plastics Industry (now the Plastics Industry Association) in the United States, but since 2008 have been administered by standards organisation ASTM International.[49]

RICs are not mandatory in all countries, but many producers voluntarily mark their products. More than half of U.S. states have enacted laws that require plastic products be identifiable.[50] The seven codes include six for the most common commodity plastics and one as a catch-all. The EU maintains a similar nine-code list that also includes ABS and polyamides.[51] RICs are not particularly important for single-stream recycling, as these operations are increasingly automated. However, in some countries citizens are required to separate their plastic waste according to polymer type before collection. For instance, in Japan PET bottles are collected separately for recycling.

Plastic identification code Type of plastic polymer Properties Common applications Melting- and glass transition temperatures (°C) Young's modulus (GPa)
Polyethylene terephthalate (PET) Clarity, strength, toughness, barrier to gas and moisture Soft drink, water and salad dressing bottles; peanut butter and jam jars; ice cream cone lids; small non-industrial electronics Tm = 250;[52]
Tg = 76[52]
2–2.7[53]
High-density polyethylene (HDPE) Stiffness, strength, toughness, barrier to gas and moisture Water pipes, gas and fire pipelines, electrical and communications conduits, five gallon buckets, milk, juice and water bottles, grocery bags, some toiletry bottles Tm = 130;[54]
Tg = −125[55]
0.8[53]
Polyvinyl chloride (PVC) Versatility, ease of blending, strength, toughness. Stretch wrap for non-food items, sometimes blister packaging. Non-packaging uses include electrical cable insulation, rigid piping and vinyl records. Tm = 240;[56]
Tg = 85[56]
2.4–4.1[57]
Low-density polyethylene (LDPE) Ease of processing; strength; flexibility; ease of sealing; moisture barrier. Frozen food bags; squeezable bottles, e.g. honey, mustard; cling films; flexible container lids Tm = 120;[58]
Tg = −125[59]
0.17–0.28[57]
Polypropylene (PP) Strength; resistance to heat, chemicals, grease and oil; moisture barrier. Reusable microwaveable ware or take-away containers; kitchenware; yogurt or margarine containers; disposable cups and plates; soft drink bottle caps. Tm = 173;[60]
Tg = −10[60]
1.5–2[53]
Polystyrene (PS) Versatility, clarity, easily formed, easily foamed Egg cartons; disposable cups, plates, trays and cutlery; foam food containers; packing peanuts and package cushioning; Tm = 240 (only isotactic);[55]
Tg = 100 (atactic and isotactic)[55]
3–3.5[53]
Other (often polycarbonate or ABS) Dependent on polymers or combination of polymers Beverage bottles, baby milk bottles. Non-packaging uses for polycarbonate: optical discs, "unbreakable" glazing, electronic apparatus housing, lenses (including sunglasses), instrument panels.[61] Polycarbonate:
Tm = 225[62]
Tg = 145;[63]
Polycarbonate: 2.6;[53] ABS plastics: 2.3[53]

Waste composition

[edit]

Plastic waste consists of various polymer types.[7][64] Polyolefins make up nearly 50% of all plastic waste and more than 90% of waste is made of thermosoftening polymers, which can be remelted

Global plastic waste by polymer type (2018)[7][64]
Polymer Waste production (Mt) Percentage of all plastic waste Polymer type Thermal character
High-density polyethylene (HDPE) 64 19.8% Polyolefin Thermoplastic
Low-density polyethylene (LDPE) 45 13.9% Polyolefin Thermoplastic
polypropylene (PP) 62 19.1% Polyolefin Thermoplastic
Polystyrene (PS) 19 5.9% Unsaturated polyolefin Thermoplastic
Polyvinyl chloride (PVC) 17 5.3% Halogenated Thermoplastic
Polyethylene terephthalate (PET) 35 10.8% Condensation Thermoplastic
Polyurethane (PUR) 18 5.6% Condensation Thermoset[65]
PP&A fibers[66] 51 15.7% Condensation Thermoplastic
All Others 12 3.7% Various Varies
Total (excludes additives) 324 100% - -

Collecting and sorting

[edit]
See caption
Bales of colour-sorted PET bottles (blues, clear and greens) Olomouc, the Czech Republic
Manual separation of co-mingled waste (2 min)
Mixed PET bottles crushed into a bale

Recycling begins with the collection and sorting of waste. Curbside collection operates in many countries. Waste is sent to a materials recovery facility or MBT plant where the plastic is separated, cleaned and sorted for sale. Unsuitable materials are sent to a landfill or incinerator. These operations account for a large proportion of the financial and energy costs associated with recycling.

Sorting plastic is more complicated than other recyclable materials because it comes in a greater range of forms. For example, glass is separated into three streams (clear, green and amber), metals are usually either steel or aluminum and can be separated using magnets or eddy current separators, and paper is usually sorted into a single stream.

Six types of commodity polymer account for about 75% of plastics waste, with the rest comprising a myriad of polymer types, including polyurethanes and synthetic fibers with a range of chemical structures. Items made from the same type of polymer may be incompatible with each other depending on the additives they contain. Additives are compounds blended into plastics to enhance performance and include stabilisers, fillers and, most significantly, dyes.[67] Clear plastics hold the highest value as they may be dyed after recycling, while black or strongly coloured plastic is much less valuable, because they affect the color of the downstream product. Thus, plastic is typically sorted by both polymer type and colour.

Various sorting approaches and technologies have been developed.[1] They can be combined in various ways.[68] In practice no approach is 100% effective.[69][70][68] Sorting accuracy varies between recyclers, producing a market where products are poorly standardised. This inconsistency is another barrier to recycling.

Manual separation

[edit]

Sorting by hand is the oldest and simplest method. In developing countries this may be done by waste pickers, while in a recycling center, workers pick items off a conveyor-belt. It requires low levels of technology and investment, but has high labor costs. Although many plastic items have identification codes workers rarely have time to look for them, so leaving problems of inefficiency and inconsistency. Even advanced facilities retain manual pickers to troubleshoot and correct sorting errors.[68] Working conditions can be unsanitary.[71]

Density separation

[edit]
Plastic densities[72]
Plastic Type Density (g/cm3)
Polyvinyl chloride 1.38-1.41
Polyethylene terephthalate 1.38-1.41
Polystyrene 1.04-1.08
High-density polyethylene 0.94-0.98
Low-density polyethylene 0.89–0.93
Polypropylene 0.85-0.92
Polystyrene foam 0.01-0.04

Plastics can be separated by exploiting differences in their densities. In this approach the plastic is first ground into flakes of a similar size, washed and subjected to gravity separation.[73] This can be achieved using either an air classifier or hydrocyclone, or via wet float-sink method.[74] These approaches provide partial sorting, as some polymers have similar density.[73] Polypropylene (PP) and polyethylene (PE) are similar as are polyethylene terephthalate (PET), polystyrene (PS), and PVC. In addition, if the plastic contains fillers, this may affect its density.[75] The lighter PP and PE fraction is known as mixed polyolefin (MPO) and can be sold as a low-value product,[76] the heavier mixed plastics fraction is usually unrecyclable.

Electrostatic separation

[edit]

In electrostatic separators, the triboelectric effect is used to charge plastic particles electrically; with different polymers charged to different extents. They are then blown through an electric field, which deflects them depending on their charge, directing them into appropriate collectors. As with density separation, the particles need to be dry, be uniform in size and shape.[77] Electrostatic separation can be complementary to density separation, allowing full separation of polymers,[78] albeit of mixed colours.

Sensor-based separation

[edit]
Photograph of the interior workings of a recycling plant
An advanced recycling plant using optical separation

This approach is largely automated and involves various sensors linked to a computer, which analyses items and directs them into appropriate chutes or belts.[79] Near-infrared spectroscopy can be used to distinguish polymer types,[80] although black/strongly-coloured plastics, as well as composite materials like plastic-coated paper and multilayered packaging, which can give misleading readings. Optical sorting such as colour sorters or hyperspectral imaging can then split by colour. Sensor based separation is more expensive to install but has the best recovery rates and produces more high-quality products.[68]

Scrap

[edit]

Plastic waste is either industrial scrap (sometimes referred to as post industrial resin) or consumer waste. Scrap is generated during production and is usually handled differently.[81] It can include flashings, trimmings, sprues and rejects. As it is collected at the point of manufacture it is clean, and of a known type and grade, and is valuable. As scrap is mostly privately traded, it is often not included in official statistics.[81]

Mechanical recycling

[edit]
Diagram showing plastic or other polymer compatibilisation.
Polymer compatibilisation

The majority of plastic waste is made of thermosoftening polymers, which can be re-melted and reformed into new items via mechanical recycling. Globally, this is by far the most common form of recycling and in many countries it is the only type practised. It is the simplest and most economical technique. It has a lower carbon footprint than other processes.[82] However, several factors can reduce output quality, which limits its applicability.[82]

Plastics are melted at anywhere between 150–320 °C (300–610 °F), depending on polymer type.[73] This is sufficient to cause unwanted chemical reactions that degrade the output.[83] This can produce volatile, low-molecular weight compounds, which may impart undesirable taste or odour, as well as discolouration. Additives can accelerate this degradation. For instance, oxo-biodegradable additives, intended to improve the biodegradability of plastic, also increase the degree of thermal degradation.[84][85] Flame retardants can similarly have unwanted effects.[86] Product quality also depends strongly on how well the plastic was sorted. Many polymers are immiscible with each other when molten and phase separate (like oil and water) during reprocessing. Products made from such blends contain boundaries between the different polymers with weak cohesion across these boundaries, compromising mechanical properties. In more extreme cases the polymers may degrade each other, particularly with PVC, as it can generate hydrogen chloride which strongly affects condensation polymers such as PET.[87]

Many of these problems have technological solutions, though they bear a financial cost. Advanced polymer stabilisers and can be used to protect plastics from the stress of thermal reprocessing.[88][89] Volatile degradation products can be removed by a range of devolatilisation techniques. Flame retardants can be removed by chemical treatment,[90] while damaging metallic additives can be rendered inert with deactivators. Finally, the properties of mixed plastics can be improved by using compatibilisers.[91][92] These are compounds that improve miscibility between polymer types to give a more homogeneous product, with better internal cohesion and improved mechanical properties. They are small-molecules possessing two chemical regions, each of which is compatible with a certain polymer. This allows them to act like molecular-nails or screws, anchoring the polymers to one another. As a result, compatibilisers are normally limited to systems dominated by two particular types of plastic and are not cost-effective for heterogeneous mixtures. No compatibiliser solves all plastic combinations. Even with these technologies, it is particularly challenging to recycle plastic so that it can meet food contact standards.

Closed-loop recycling

[edit]

In closed-loop, or primary recycling, used plastic is endlessly recycled back into new items of the same quality and type. For instance, turning drinks bottles back into drinks bottles. It can be considered an example of a circular economy. The continual mechanical recycling of plastic without reduction in quality is challenging due to cumulative polymer degradation[93] and risk of contaminant build-up. In 2013 only 2% of plastic packaging was recycled in a closed loop.[94] Although closed-loop recycling has been investigated for many polymers,[93] to-date the only industrial success is with PET bottle recycling.[95] This is because polymer degradation in PET is often repairable. PET's polymer chains tend to cleave at their ester groups and the alcohol and carboxyl groups left by this can be joined back together by the use of chemical agents called chain extenders.[96] Pyromellitic dianhydride is one such compound.

Open-loop recycling

[edit]
Photograph of a re-usable carrier bag made from recycled plastic bottles processed using open-loop recycling.
This re-usable carrier bag has been made from recycled plastic bottles. It is an example of open-loop recycling.

In open-loop recycling, also known as secondary recycling, or downcycling, the quality of the plastic is reduced each time it is recycled, so that the material eventually becomes unrecyclable. It is the most common type.[94] Recycling PET bottles into fleece or other fibres is a common example, and accounts for the majority of PET recycling.[97] Life-cycle assessment shows it to be of ecological benefit.[98][3][97] Recycling can displace demand for fresh plastic.[99] However, if it is used to produce items that would not otherwise have been made, then it is not displacing production and is of little or no benefit to the environment.

The reduction in polymer quality can be offset by mixing recycled and new materials. Compatibilised plastics can be used as a replacement for virgin material, as it is possible to produce them with the right melt flow index needed for good results.[100] Low quality mixed plastics can be recycled in an open-loop, although demand for such products is limited. When these are mixed during reprocessing the result is usually an unappealing dark-brown. These blends find use as outdoor furniture or plastic lumber. As the material is weak, but of low cost, it is produced in thick planks to provide material strength.

Thermosets

[edit]

Although thermoset polymers do not melt, technologies have been developed for their mechanical recycling. This usually involves breaking the material down to small particles (crumbs), which can then be mixed with a binding agent to form a composite material. For instance, polyurethanes can be recycled as reconstituted crumb foam.[101][102]

Feedstock recycling

[edit]

In feedstock recycling, also called chemical recycling or tertiary recycling, polymers are reduced to their chemical building-blocks (monomers), which can then be polymerised back into fresh plastics.[103][104][105] In theory, this allows for near infinite recycling; as impurities, additives, dyes and chemical defects are completely removed with each cycle.[106][107] In practice, chemical recycling is far less common than mechanical recycling. Implementation is limited because technologies do not yet exist to reliably depolymerise all polymers on an industrial scale and also because the equipment and operating costs are much higher. In 2018 Japan had one of the highest rates in the world at ~4%, compared to 23% mechanical recycling,[108] in the same period Germany, another major recycler, reported a feedstock recycling rate of 0.2%.[109] Depolymerising, purifying and re-polymerising the plastic can also be energy intensive, leading to the carbon footprint of feedstock recycling normally being higher than that of mechanical recycling.[82] PET, PU and PS are depolymerised commercially to varying extents,[106] but the feedstock recycling of polyolefins, which make-up nearly half of all plastics, is much more limited.[107]

Thermal depolymerisation

[edit]

Certain polymers like PTFE, polystyrene, nylon 6, and polymethylmethacrylate (PMMA) undergo thermal depolymerisation when heated to sufficiently high temperatures.[110] The reactions are sensitive to impurities and require clean and well sorted waste to produce a good product. Even then, not all depolymerisation reactions are completely efficient and some competitive pyrolysis is often observed; the monomers, therefore, require purification before reuse. The feedstock recycling of polystyrene has been commercialised,[107] but global capacity remains fairly limited.

Chemical depolymerisation

[edit]

Condensation polymers bearing cleavable groups such as esters and amides can be completely depolymerised by hydrolysis or solvolysis. This can be a purely chemical process but may also be promoted by enzymes such as PETase.[111][112] Such technologies have lower energy costs than thermal depolymerisation but are not available for all polymers. Polyethylene terephthalate has been the most heavily studied polymer,[113] and has reached commercial scale.[106]

Energy recovery

[edit]
Photograph of piles of trash including large amounts of plastic at an incinerator
Piles of trash including large amounts of plastic at an incinerator in Ko Tao, Thailand. Well regulated incinerators reduce harmful toxins released during the burning process, but not all plastic is burned in proper facilities.

Energy recovery, also called energy recycling or quaternary recycling, involves burning waste plastic in place of fossil fuels for energy production.[114][4] It is included in the recycling data reported by many countries,[115][116] although it is not considered recycling by the EU.[117] It is distinct from incineration without energy recovery, which is historically more common, but which does not reduce either plastic production or fossil fuel use.

Energy recovery is often the waste management method of last resort, a position previously held by landfill. In urban areas a lack of suitable sites for new landfills can drive this,[118] but it is also driven by regulation, such as the EU's Landfill Directive or other landfill diversion policies. Compared to the other recycling options, its appeal is largely economic. If the correct technologies are used, then the plastics do not need to be separated, or from other municipal solid waste (garbage), which reduces costs. Compared to the sometimes variable market for recyclables, demand for electricity is universal and better understood, reducing the perceived financial risk. As a means of waste management, it is highly effective, reducing the volume of waste by about 90%, with the residues sent to landfill or used to make cinder block. Although its CO2 emissions are high, comparing its overall ecological desirability to other recycling technologies is difficult.[3] For instance, while recycling greatly reduces greenhouse gas emissions compared to incineration, it is an expensive way of achieving these reductions when compared to investing in renewable energy.[119]

Plastic waste may be burnt as refuse-derived fuel (RDF)[120], or it may be chemically converted to a synthetic fuel first. In either approach PVC must be excluded or compensated for by installing dechlorination technologies, as it generates large amounts of hydrogen chloride (HCl) when burnt. This can corrode equipment and cause undesirable chlorination of fuel products.[121] Burning has long been associated with the release of harmful dioxins and dioxin-like compounds, however these hazards can be abated by the use of advanced combustors and emission control systems. Incineration with energy recovery remains the most common method, with more advanced waste-to-fuel technologies such as pyrolysis hindered by technical and cost hurdles.[118][122]

Waste-to-fuel

[edit]

Mixed plastic waste can be depolymerized to give a synthetic fuel. This has a higher heating value than the starting plastic and can be burnt more efficiently, although it remains less efficient than fossil fuels.[123] Various conversion technologies have been investigated, of which pyrolysis is the most common.[124][125] Conversion can take place as part of incineration in an IGC cycle, but often the aim is to collect the fuel to sell it. Pyrolysis of mixed plastics can give a fairly broad mix of chemical products (between 1 and 15 carbon atoms) including gases and aromatic liquids.[126][127][128] Catalysts can give a better-defined product with a higher value.[129][130][131] Liquid products can be used as synthetic diesel fuel,[132] with commercial production in several countries.[133] Life-cycle analysis shows that plastic-to-fuel can displace fossil fuels and lower net greenhouse gas emissions (~15% reduction).[134]

Compared to the widespread practise of incineration, plastic-to-fuel technologies have struggled to become economically viable.[124][135]

Other uses

[edit]

Coke replacement

[edit]

Many kinds of plastic can be used as a carbon source (in place of coke) in scrap steel recycling,[136] with roughly 200,000 tonnes of waste plastics processed each year in Japan.[137]

Construction and concrete

[edit]

The use of recovered plastics in engineering materials is gaining ground.[138] Ground plastic may be used as a construction aggregate or filler material in certain applications.[139][140] While generally unsuitable in structural concrete, plastic's inclusion in asphalt concrete, (forming rubberised asphalt), subbase and recycled insulation can be beneficial.[141] An example of this is the construction of plastic roads. These may be made entirely of plastic or can incorporate significant amounts of plastic. The practice is popular in India, which by 2021 had constructed some 700 km (435 miles) of highways.[142] It may allow the leaching of plastic additives into the environment.[143] Research is ongoing to use plastics in various forms in cementitious materials such as concrete. Densifying plastic materials such as PET and plastic bags and then using them to partially replace aggregate and depolymerizing PET to use as a polymeric binder to enhance concrete are under study.[144][145][146]

Criticism

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Plastic recycling research showed that most plastic could currently not be economically recycled.[18][147][19][148] This has resulted in occasions where plastic waste dropped into recycling bins has not been recycled, and been treated as general waste.[149] Resin identification codes are based on the recycling symbol, but have drawn criticism, as they imply that marked items are always recyclable when this may not be true.[150]

See also

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Sources

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 This article incorporates text from a free content work. Licensed under Cc BY-SA 3.0 IGO (license statement/permission). Text taken from Drowning in Plastics – Marine Litter and Plastic Waste Vital Graphics​, United Nations Environment Programme.

References

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Revisions and contributorsEdit on WikipediaRead on Wikipedia
from Grokipedia

Plastic recycling is the reprocessing of discarded plastic waste through collection, sorting by type using resin identification codes, cleaning, shredding, melting, and extrusion into pellets or sheets for reuse in new items, primarily via mechanical methods for thermoplastics like PET and HDPE.
Despite its goal of conserving resources and curbing , empirical data indicate that global plastic rates have stagnated at around 9% of generated waste, with over 70% mismanaged through landfilling, , or leakage into the environment, undermining claims of substantial environmental mitigation.
Major obstacles include material contamination, polymer incompatibility requiring extensive sorting, quality degradation necessitating into lower-value products, and economic barriers where virgin plastic production—fueled by abundant fossil feedstocks—remains cheaper than recycled alternatives.
Controversies center on the limited of mechanical for mixed or multilayer plastics, the energy-intensive nature of chemical recycling processes that may offset benefits through emissions and costs, and the broader systemic failure where rising plastic production outpaces recycling infrastructure development.

History

Origins and Technological Development

The post-World War II era marked the onset of widespread plastic production, with output rising 300% during the war due to material shortages and synthetic innovations, followed by continued expansion into consumer goods amid . This boom in thermoplastics, including (PE) developed in the 1930s and high-density polyethylene (HDPE) commercialized in 1953, generated increasing waste volumes that prompted initial recycling efforts focused on reprocessing through mechanical means like grinding and remelting. However, engineering hurdles such as thermal degradation—where repeated heating shortened chains and reduced material strength—and difficulties in separating mixed resins limited scalability for until process refinements in sorting and purification emerged. Mechanical recycling techniques advanced in the 1950s and 1960s primarily for industrial applications, involving shredding, , and of compatible thermoplastics like HDPE and (PP, invented 1951), but consumer-scale implementation lagged due to inconsistent feedstock quality and lack of standardized collection. The first dedicated facility for post-consumer plastic waste opened in , in 1972, pioneering mechanical processing pipelines that included density-based separation and melt filtration to yield pellets for reuse, though output purity remained challenged by additives and contaminants. For (PET), initially patented for fibers in 1941 but adapted for bottles by Nathaniel Wyeth in 1973, mechanical recycling debuted commercially in the United States in 1977, converting shredded bottles into flakes via hot and , with early yields constrained by sensitivity and color inconsistencies. Parallel early efforts in chemical recycling explored to revert polymers to , with aminolysis techniques reported in the for polyesters and polyamides, breaking or bonds using amines under heat. These processes faced prohibitive energy demands—often exceeding 500 kJ/mol for bond cleavage—and low recovery rates below 70% due to side reactions forming oligomers, rendering them non-viable for large-scale adoption amid cheaper virgin production. Such limitations underscored causal barriers in and kinetics, where favored degradation over clean reversal without catalysts, stalling progress until later decades.

Industry Promotion and Deception

In 1974, chairman Irving S. stated in an internal industry speech that large-scale recycling of plastics faced "serious doubt" of ever becoming economically viable, reflecting widespread executive awareness of technical and cost barriers to widespread plastic recovery. Despite this, the Society of the Plastics Industry adopted the "chasing arrows" —originally designed in 1970 for general recyclables—in 1988 to label resin identification codes for plastics, creating consumer confusion that implied broad recyclability even for types with low recovery rates. Petrochemical companies including and Dow Chemical funded recycling research and public campaigns through organizations like the Society of the Plastics Industry during the 1980s and 1990s, investing millions in programs such as curbside collection pilots while simultaneously scaling up virgin plastic production capacity by over 200% globally from 1980 to 2000. Internal documents uncovered in a 2024 Center for Climate Integrity analysis reveal that these firms viewed recycling promotion as a strategy to avert stricter production limits or bans, with Exxon executives in 1989 noting it could "buy time" against environmental pressures. This emphasis on consumer-led recycling shifted accountability from producers to individuals, fostering policies that prioritized infrastructure over reductions in single-use plastics and contributing to delays in legislative bans; for instance, U.S. industry lobbying in the and repeatedly weakened or reversed state-level prohibitions by arguing sufficed as an alternative. As a result, global production grew from 110 million metric tons in 1990 to over 400 million in 2023, while end-of-life rates for plastics hovered below 10% annually.

Global Trade Shifts and Regulatory Responses

From the through the 2010s, developed nations substantially increased exports of plastic waste to developing countries in , driven by lower processing costs and limited domestic infrastructure. The , , , , and the emerged as primary exporters, with shipments often routed through transit hubs like to , which became the dominant importer absorbing a plurality of global plastic scrap volumes. By 2016, global plastic waste trade had expanded significantly from under 0.32 million tonnes in 1988, with receiving the bulk of exports from countries. In 2018, 's "National Sword" policy imposed stringent contamination limits of 0.5% and effectively banned imports of most non-industrial plastic waste, slashing its imports from 5.7 million tonnes in 2017 to under 0.06 million tonnes in 2018—a decline of over 99%. This abrupt restriction displaced an estimated 100 million metric tonnes of plastic waste globally over subsequent years, reducing overall volumes by approximately one-third and causing stockpiling, diversions, and declines in rates in exporting nations. U.S. exports of recyclable plastics to specifically fell by 91.4% in quantity from 2017 to 2018, exposing vulnerabilities in supply chains reliant on foreign processing and highlighting inadequate domestic sorting and capacities. Post-ban, plastic waste flows shifted to Southeast Asian countries such as , , , and , which saw import surges before implementing their own restrictions starting in , further disrupting global trade patterns. These developments underscored systemic dependencies on export markets and prompted regulatory reevaluations, though alternative destinations often lacked sufficient infrastructure, leading to increased mismanagement and environmental leakage. In response, the strengthened export controls via the Waste Shipment Regulation (EU) 2024/1157, prohibiting non-recyclable plastic waste shipments to non-OECD countries and mandating prior for others, while advancing (EPR) frameworks to shift costs to producers. , state-level EPR initiatives expanded in 2024, particularly for , aiming for producer-funded collection and systems, but federal uniformity remains absent, with enforcement and efficacy data as of 2025 showing mixed implementation and persistent export challenges. These measures seek to internalize but have yet to fully mitigate trade disruptions or build resilient domestic infrastructures.

Processes and Technologies

Collection and Sorting Methods

Plastic waste collection primarily occurs through curbside programs or deposit-return systems (DRS). Curbside collection, widespread in the United States, involves residents placing recyclables in a single bin or separate streams for municipal pickup, but single-stream systems—where all recyclables mix during transport—often result in rates of 20-30% from non-recyclable materials and improper sorting by households, reducing the quality of collected plastics. In contrast, DRS incentivize returns of beverage containers via refunds, achieving collection rates up to 90% for targeted plastics like PET bottles, far exceeding curbside yields without such economic motivators. At material recovery facilities (MRFs), sorting begins with manual inspection to remove obvious contaminants, followed by mechanical methods like density separation via sink-float tanks, which exploit differences in specific gravity (e.g., PET floats while PVC sinks). Automated technologies, including near-infrared (NIR) spectroscopy introduced commercially in the early 2000s, scan surfaces to identify polymer types based on molecular absorption spectra, enabling high-speed separation of resins like HDPE from PET with accuracies over 95% under optimal conditions. Multi-layer packaging, comprising films or laminates bonded with adhesives and barrier materials like aluminum or EVOH, poses severe sortability issues due to inseparable layers that defy or NIR differentiation, often contaminating sorted streams and yielding mixed outputs with purity below 50% by weight. Germany's Duales System Deutschland (DSD), established in 1991 under producer responsibility with "Green Dot" fees on packaging, coordinates separate collection via yellow bins for plastics, achieving initial yields of marketable recyclables around 70% through dedicated streams and contractual standards, outperforming undifferentiated systems. In the , single-stream dominance has amplified inefficiencies, with processors reporting elevated residue from entangled contaminants—such as food waste or films—necessitating costly manual remediation and yielding lower-grade bales that processors reject or at rates up to 25%.

Mechanical Recycling Techniques

Mechanical recycling involves the physical processing of plastic waste, primarily thermoplastics, to produce secondary materials or products without altering the polymer's chemical structure. This method is suitable for resins like , , and , which can be repeatedly softened by heat. The process typically begins with shredding sorted plastic items into flakes, followed by washing to remove contaminants such as labels, adhesives, and residues, drying, melting, and into pellets or sheets for . The technique excels for single-resin streams, such as PET bottles, where uniform composition minimizes separation challenges. For instance, post-consumer PET bottles undergo flaking, hot washing at temperatures around 80-90°C to eliminate impurities, and into recycled PET (rPET) pellets, which are then used in applications like fibers or . In the United States, a significant share of mechanically recycled PET has been converted into fibers for clothing and upholstery, diverting substantial volumes from landfills prior to stricter export regulations in 2018-2019. However, achieving closed-loop —reprocessing into identical products like new bottles—remains limited, with bottle-to-bottle rPET comprising only about 20-30% of uses due to purity demands for food-contact applications. Polymer degradation imposes inherent limits, as repeated mechanical processing induces chain scission from thermal, shear, and oxidative stresses, reducing molecular weight and after 2-3 cycles. This manifests in diminished mechanical properties, such as lower tensile strength and increased , necessitating blending with virgin resin or into lower-value items like non-food or fillers. Empirical studies confirm that for polyolefins, each recycling loop shortens chains via random scission, while polyesters like PET suffer during washing, further eroding performance unless mitigated by additives. Real-world yields often fall below theoretical maxima—typically 70-90% material recovery—owing to persistent impurities like mixed polymers or metals, which degrade output quality and economic viability. Thermoset plastics, including epoxies and phenolics, resist mechanical recycling due to their irreversible cross-linked networks, which prevent melting and reforming. Grinding thermosets yields powders for fillers in composites or asphalt, but this downcycles them into non-structural roles with low value recovery, as the rigid structure retains no processability. exacerbates losses, with even trace thermoplastics complicating separation and reducing filler purity to below 80% in practice.

Chemical and Feedstock Recycling

Chemical recycling processes dismantle plastic polymers at the molecular level into monomers, oligomers, or hydrocarbon feedstocks, enabling the production of new plastics or fuels from waste that is often unsuitable for . Unlike mechanical methods, these techniques employ heat, catalysts, solvents, or to break chemical bonds, targeting mixed or contaminated streams such as multilayer . Key variants include , , and , each with distinct operational parameters and outputs. Pyrolysis entails heating plastics in an oxygen-free environment at 400–800°C, decomposing them into liquid (primarily hydrocarbons), non-condensable gases, and solid char residue. The oil serves as a drop-in feedstock for steam crackers to generate monomers like and , but mass recovery for plastic production typically yields less than 50% due to 20–30% char losses and gaseous byproducts, with effective plastic-to-plastic conversion often as low as 15–20% in pilot-scale operations processing mixed waste. operates at higher temperatures (800–1,200°C) with controlled oxygen or , converting plastics primarily to (CO and H₂) for or fuel, though it demands energy for and subsequent upgrading, resulting in comparable mass inefficiencies from and formation. Depolymerization targets specific polymers, such as PET via or to yield and , or through acid/base , achieving recoveries up to 90% for pure feeds but faltering with contaminants or non-condensation plastics like polyolefins, which comprise most waste volumes. Feedstock recycling integrates these outputs into virgin production cycles, yet inherent losses—exacerbated by sorting limitations and process —constrain overall efficiency, often necessitating blending with fossil-derived materials. Commercial deployment lags despite hype, with over 169 global announcements for advanced facilities as of 2024, yet fewer than 10% achieving meaningful scale-up by 2025 amid delays, yield inconsistencies, and high demands from endothermic reactions and purification steps. pilots, for instance, frequently underperform on throughput, with 2025 projections indicating over 50% of slated projects missing timelines due to technical hurdles in handling real-world variability. Firms like Quantafuel, employing catalytic for oil production, have expanded partnerships for feedstock supply but contend with output fluctuations requiring subsidies, underscoring the gap between pilot successes and industrial viability.

Energy Recovery Processes

Energy recovery processes for waste primarily involve thermal treatments such as direct in waste-to-energy (WTE) incinerators and thermochemical conversion via or , which generate usable , , or fuels from non-recyclable fractions. In direct , waste is burned at high temperatures (typically 850–1100°C) in controlled facilities equipped with boilers to produce steam for or , achieving electrical efficiencies of 14–28% and overall of 20–30% when including . , conducted in oxygen-free environments at 400–600°C, decomposes plastics into , oils, and char, with the gaseous and liquid products combusted for , yielding up to 60–80% conversion to combustible fuels depending on feedstock and process conditions. These methods exploit the high calorific value of plastics, akin to , to offset use, in contrast to landfilling, which recovers zero energy and risks long-term environmental leakage. In , where (MSW) rates reach approximately 75–79%, is integrated into over 1,000 facilities, generating power and heat equivalent to millions of households while minimizing reliance to under 2%. Following China's 2018 ban on plastic waste imports, the shifted toward domestic handling under the Waste Framework Directive, promoting WTE for residual wastes over unregulated exports, with facilities required to meet R1 standards (≥60% for heat/electricity combined in some cases) to qualify as recovery rather than disposal. Globally, while only about 12% of MSW undergoes via , this diverts plastics from the 60% landfilled or mismanaged, providing a pragmatic outlet for contaminated or mixed streams unsuitable for mechanical recycling. Modern WTE plants employ advanced emission controls, including activated carbon injection, selective catalytic reduction, and baghouse filters, reducing dioxin and furan outputs to below 0.1 ng TEQ/Nm³—levels comprising less than 0.2% of total industrial emissions—far surpassing pre-1990 uncontrolled incinerators. However, incineration of fossil-derived plastics releases CO₂ emissions comparable to direct fossil fuel combustion on an energy-equivalent basis, approximately 2.5–3 kg CO₂ per kg plastic, without biogenic offsets, necessitating integration with carbon capture for net-zero alignment. These processes thus serve as a bridge for managing plastic waste volumes exceeding low recycling diversion rates (globally ~9%), prioritizing energy extraction over indefinite storage.

Recycling Rates and Statistics

Global production has expanded dramatically since the , reaching approximately 400 million metric tons annually by , yet rates have remained persistently low. According to a comprehensive analysis, less than 10% of all ever produced worldwide has been recycled, a figure that has shown minimal improvement over decades despite widespread promotion of programs. In 2019, only 9% of generated that year was recycled, with the rate stagnating at around this level through subsequent years, including no significant change by 2025. Historical data reveal a plateau in recycling fractions, even as production volumes surged from 2 million tons in 1950 to over 450 million tons by the . Annual global rates hovered near 9% from the early 2000s onward, with plastic generation doubling from 156 million tons in 2000 to 353 million tons in 2019, yet effective outputs failed to scale proportionally. This stagnation is exemplified in the United States, where the post-consumer plastic rate declined from approximately 9% in 2015 to 5-6% by 2021, reflecting broader trends in developed economies. Distinctions between cumulative and annual metrics underscore the limited longevity of recycled materials; most plastics undergo at most one process—often into lower-value products like textiles or construction fillers—before being landfilled or incinerated, contributing little to multi-loop circularity. Of the small fraction recycled, effective in high-quality applications remains under 1% historically, as , degradation, and economic factors limit repeated processing. This pattern highlights that, despite over 70 years of industry growth and recycling initiatives, the overall recycled fraction of plastics has not exceeded single digits globally.

Regional Variations and Data

In , stringent EU directives on , including targets for separate collection and quotas, have driven higher plastic rates compared to other regions, though plastic-specific figures lag behind overall municipal waste recovery. The achieved a 42.1% rate for plastic packaging waste in 2023, up from 40.7% in 2022, supported by infrastructure for source separation and mechanical processing. In , policy enforcement via the Packaging Act has yielded a plastic packaging rate exceeding 50% in 2022, exceeding the average due to advanced sorting facilities and deposit-return systems for bottles, though overall post-consumer plastics stood at approximately 27% continent-wide in recent assessments. North America exhibits lower rates, influenced by decentralized policies and reliance on voluntary programs without federal mandates for plastics. Plastic waste generation in the is among the highest globally, estimated at 42–51 million metric tons annually in recent years. The post-consumer plastic recycling rate stands at approximately 5–6% according to independent analyses, down from the EPA's 8.7% figure for 2018, with roughly 94% managed through landfilling (75–80%), incineration with energy recovery (12–16%), and a smaller mismanaged fraction (1–5%). The mismanaged portion drives domestic environmental leakage, with plastic entering rivers and coastal waters via stormwater runoff, urban sources, and major waterways like the Mississippi River, contributing to microplastic contamination in water, soils, and wildlife. Following China's 2018 National Sword policy, U.S. exports of plastic scrap stabilized at 200,000–250,000 metric tons annually, representing 5–10% of collected material, with primary destinations including Canada, Mexico, Malaysia, India, Indonesia, and Vietnam. In recipient countries, particularly in Southeast Asia, limited infrastructure leads to high mismanagement rates of 50–75%, resulting in open dumping, burning, and leakage into rivers and oceans, as documented in OECD analyses and studies like Jambeck et al. (2015). Challenges in curbside collection consistency and in mixed streams persist, with only about 29% recovery for specific resins like PET bottles. Canada's rate hovers around 6%, hampered by similar infrastructural gaps despite provincial initiatives. In , the 2018 Chinese import ban on plastic waste redirected global flows, boosting domestic processing in some nations but exposing informal sectors' limitations. recycles about 13% of plastic waste formally as of recent data, with informal collection and processing handling up to 20-30% in urban areas like , though this often involves open burning and leaching pollution absent regulatory oversight. 's effective rate ranges from 6-14% in , per regional analyses, with post-ban imports straining under-equipped facilities and leading to marine leakage. Emerging markets in and the face collection deficits, yielding formal recycling rates below 5-10%, as weak infrastructure prioritizes landfilling over segregation. The recycles roughly 5-7% of plastics, with 90% landfilled, though Gulf states like the UAE are piloting schemes to incrementally raise figures. mirrors this, with rates under 10% due to urban-rural disparities in waste pickup, exacerbating open dumping.
Region/CountryPlastic Recycling Rate (Recent Estimate)Key Influencing Factor
(Packaging)42.1% (2023)EU collection
(Packaging)>50% (2022)Deposit systems
5% (2023)No national mandate
~13% (formal, ~2019-2023)Informal sector dominance
(e.g., )6-14%Post-ban import pressures
5-7% preference

Barriers to Higher Recycling Rates

Plastics generally have much lower recycling rates than materials like paper (60-70%), glass (30-40%), or metals such as aluminum (over 40%), due to technical challenges including contamination, polymer incompatibility, and quality degradation, as well as economic factors where virgin plastic production remains cheaper. Contamination from residues and non-plastic materials significantly hinders plastic , often rendering collected items unusable and leading to rejection rates of up to 25% in U.S. residential recycling streams. waste adhering to plastics like PET bottles degrades material quality during processing, necessitating costly cleaning or outright disposal, while mixed-in contaminants such as or metals complicate sorting. In the U.S., experts estimate that 20% to 70% of exported plastic recyclables are ultimately discarded due to such impurities, exacerbating low overall recovery. Mixing of incompatible resin types further caps recycling efficiency, as plastics like and polypropylene (PP) cannot be easily separated or compatibilized without advanced, energy-intensive interventions. Post-consumer waste streams contain diverse polymers that, when blended, result in lower-quality recycled outputs unsuitable for high-value applications, limiting closed-loop reuse. Mechanical recycling processes struggle with these heterogeneities, often yielding downcycled products or requiring , which remains technically limited for mixed resins. Product design, particularly multi-layer packaging combining plastics with barriers like aluminum or EVOH, poses insurmountable separation challenges for standard facilities, as adhesives and thin layers resist without specialized equipment. These structures, common in food wrappers and pouches, contaminate sorted streams and increase processing complexity, with global prevalence undermining mono-material recycling mandates. Industry analyses emphasize the need for single-resin designs to enhance sortability, yet widespread adoption lags due to performance trade-offs in barrier properties. Logistical scale mismatches amplify these barriers, with global plastic production exceeding 430 million metric tons annually in recent years, while recycling infrastructure handles far less—global rates hover around 9%, implying processed volumes under 40 million tons. This disparity stems from insufficient sorting and reprocessing capacity relative to generation, compounded by geographic concentrations of facilities unable to match dispersed collection volumes. Expanding capacity requires overcoming material science limits on handling degraded or mixed feedstocks at industrial scales.

Economic Realities

Production Costs Compared to Virgin Plastics

Recycled plastics consistently incur higher production costs than virgin plastics due to the labor-intensive processes of collection, sorting, cleaning, and reprocessing, which introduce inefficiencies not present in the streamlined production of virgin materials. For (PET), virgin resin prices in mid-2025 hovered around €1,000 per metric ton, while food-grade recycled PET (rPET) pellets commanded a premium of approximately €600 per metric ton, reflecting overheads from contamination removal and quality downgrading. Similarly, for (HDPE), mechanical costs in exceed virgin production by nearly double, driven by feedstock variability and lower yield rates from mixed waste streams. These disparities stem from the favoring virgin production, where crude oil derivatives benefit from high-volume , whereas yields inconsistent material purity requiring additional purification steps. Oil price volatility exacerbates the cost gap, as declines in crude prices—such as those persisting from the early —reduce virgin feedstock expenses while recycled prices remain elevated due to fixed costs. During the 2020 price collapse, virgin plastics became cheaper than recycled counterparts, prompting manufacturers to revert to virgin materials where feasible, widening the economic disadvantage for . Post-COVID supply chain disruptions caused rPET prices to spike by up to 50% in some markets by late 2021, yet subsequent price stabilization maintained recycled premiums, with rPET regaining significant margins over softening virgin PET prices into 2024. Late 2025 reports indicated recycled HDPE pellet prices expected to remain flat through the rest of 2025, with potential increases in early 2026 due to demand factors; however, in January 2026, R-PET clear food-grade pellet prices declined by €20 per tonne amid low demand and oversupply. Broader resin market outlooks suggest 2026 could mark the end of a down cycle, potentially stabilizing or improving prices. Low environments, like the €330 per scrap price versus higher virgin equivalents in 2023, underscore how advantages amplify 's uncompetitiveness absent external interventions. Viability for recycled plastics demands high collection purity thresholds, typically exceeding 60-70% clean, single-polymer streams to minimize reprocessing losses and achieve against virgin costs, conditions seldom met in municipal systems plagued by cross-contamination. Studies indicate that substitution ratios below 70% for HDPE fail to offset recycling's embedded costs relative to virgin production, rendering most operations uneconomic without purity enhancements via advanced sorting. Contamination rates above 10-20% in sorted bales necessitate costly , further eroding margins and limiting , as evidenced by persistent issues in global waste streams. McKinsey analyses highlight that integrated economic models for plastics recovery require granular purity controls to approach competitiveness, yet real-world collection yields rarely suffice, perpetuating reliance on virgin feedstocks.

Market Incentives, Subsidies, and Viability

(EPR) schemes in the aim to internalize costs for plastic producers, mandating them to finance collection, sorting, and infrastructure to meet targets such as 55% of plastic by 2030. However, despite widespread implementation since the early , these programs have yielded only modest increases in rates, reaching 42.1% for plastic in 2023, far below aspirational goals and indicating limited effectiveness in driving systemic change without stricter enforcement. Analyses of EPR frameworks highlight marginal impacts on waste reduction and eco-design, as producer fees often prioritize compliance over innovation, with enforcement varying by and resulting in uneven uptake. Government subsidies have attempted to bolster recycling viability, particularly for advanced chemical recycling technologies. In the United States, the 2022 allocated $10 billion through the Qualifying Advanced Energy Project Credit (Section 48C) to support facilities producing recycled plastics and related equipment, aiming to expand capacity amid low mechanical recycling rates. Yet, economic pressures persist, as evidenced by multiple European plant closures and project cancellations in 2025, including those by Borealis, Dow, and , due to insufficient feedstock supply, volatile markets, and inability to compete without ongoing support. By the end of 2025, is projected to lose nearly 1 million metric tons of recycling capacity since 2023, underscoring recycling's reliance on non-market interventions rather than standalone profitability. Private sector dynamics further reveal viability challenges, with virgin plastic producers often resisting mandates that favor recycled content. Major petrochemical firms have lobbied against stringent EPR expansions and production caps, such as in New York State's Packaging Reduction and Recycling Infrastructure Act, where over 100 businesses opposed measures in early 2025 to protect low-cost virgin material dominance. This opposition stems from recycled plastics' inconsistent quality and higher processing demands, limiting market substitution to under 10% globally, and highlights how incentives alone fail without enforced demand or penalties on virgin alternatives. Overall, recycling operations depend heavily on subsidies and regulatory props, as unsubsidized models collapse under competition from inexpensive fossil-based feedstocks.

Trade and Supply Chain Economics

Prior to 's 2018 ban on most plastic waste imports, global trade flows favored exporting scrap to , where low labor costs and lax environmental regulations enabled processing at approximately $50-100 per ton, compared to over $200 per ton for domestic handling in the United States and due to stricter standards and higher operational expenses. absorbed over 50% of traded plastic waste in 2016, subsidizing low collection costs in exporting nations but creating dependency on this . The ban, effective from January 2018, reversed these economics by curtailing imports from 600,000 metric tons in to near zero, redirecting flows to and amplifying burdens on domestic systems in developed economies, where unexportable waste led to processing backlogs, price crashes for recyclables, and increased landfilling. Global plastic waste trade volumes subsequently declined, with data showing a continued downward trend through 2023 as alternative markets like and imposed their own restrictions, further straining supply chains. By 2025, emerging market destinations such as contend with economic pressures requiring at least 63% rates for imported plastic waste to achieve viability—exceeding domestic rates by over 40 percentage points—as importing low-value often results in net losses without high recovery mandates. These thresholds highlight chokepoints in global chains, where importers must offset transportation costs and contamination risks against volatile output markets. Scrap price instability exacerbates these issues; high-density polyethylene (HDPE) bale prices, for example, surged from about $700 per metric in July 2024 to $1,920 per metric by March 2025 amid supply shortages, while virgin HDPE remained relatively stable at around $1,227 per metric in mid-2025. This volatility, driven by fluctuating export bans and regional demand, contrasts with the predictability of virgin material supply, undermining long-term recycling trade reliability.

Environmental and Impact Assessments

Claimed Benefits of Recycling

Proponents of plastic recycling assert that it conserves natural resources by substituting recycled materials for virgin petroleum-based feedstocks, thereby reducing the demand for crude oil extraction and refining. Lifecycle analyses indicate that manufacturing recycled (PET) requires up to 70% less energy than producing equivalent virgin PET, primarily due to avoided extraction and processes. This energy differential is attributed to the lower thermal and mechanical inputs needed for mechanical recycling of sorted PET flakes compared to synthesizing new from hydrocarbons. Recycling is also claimed to divert plastic waste from landfills, mitigating potential methane emissions from anaerobic decomposition in such sites, though plastics degrade slowly. In Germany, where over 71% of packaging waste was recycled in 2019 following strict landfill bans implemented since 2005, these diversion policies have contributed to substantial reductions in landfill methane emissions across the waste sector. Advocates highlight that such programs prevent the accumulation of non-biodegradable plastics in landfills, preserving space and reducing long-term environmental burdens associated with waste burial. Economically, plastic recycling is promoted for creating jobs in collection, sorting, , and sectors. The global and industry, encompassing plastics, supported an estimated 6.9 million jobs as of 2024, representing about 0.2% of total worldwide employment, though many are in informal, low-wage activities in developing regions. In the U.S., plastic recycling operations alone sustained over 164,000 direct jobs in 2019, with multipliers extending to roles. These figures are cited by industry groups as evidence of recycling's role in fostering employment, particularly in labor-intensive .

Actual Lifecycle Emissions and Pollution

Lifecycle assessments of mechanical plastic recycling indicate greenhouse gas (GHG) emission reductions of approximately 1-3 tons of CO2 equivalent per ton compared to virgin plastic production, primarily due to avoided extraction and energy demands. For specific polymers like (HDPE), mechanical recycling achieves up to 90% lower carbon emissions relative to virgin material. However, these savings diminish with and sorting inefficiencies, which increase use in preprocessing steps such as and shredding. Chemical recycling methods, including , exhibit higher lifecycle emissions, often 9 times those of mechanical recycling, due to intensive heating requirements (typically 400-600°C) and energy inputs for . For instance, of plastic packaging generates 2.91 kg CO2eq per kg of recyclate, compared to 0.311 kg CO2eq per kg for mechanical processes. These elevated figures arise from fossil fuel-derived process heat and incomplete yield efficiencies, where only 0.1-6% of input mass may yield usable monomers in practice. Plastic recycling processes contribute to through mechanical actions like shredding and , generating particles as small as under 10 µm that enter streams. Studies estimate that 6-13% of incoming plastic mass at facilities converts to microplastics during these stages, with filtration often insufficient to capture fines below 10 µm before discharge. Recycled products further exacerbate via leaching of additives, including legacy contaminants like brominated flame retardants at elevated concentrations compared to virgin plastics. A 2025 analysis identified over 80 chemicals leaching from recycled plastics into water, inducing biological disruptions in aquatic organisms such as altered metabolism. Downcycling in recycling—where material quality degrades due to scission and —limits reuse to one or two cycles before disposal, effectively routing most output back to landfills and negating emission savings over time. In the United States, approximately 85% of , including downcycled fractions, ended up in landfills as of 2021, with global rates hovering at 9% and residues comprising 40% of collected material. This pathway perpetuates burdens, as degraded recyclates release additives and during eventual landfilling or .

Comparisons to Landfilling, Incineration, and Reduction Strategies

Incineration of plastic waste enables energy recovery, typically generating 500–600 kWh per metric ton in waste-to-energy facilities, due to plastics' high calorific value of 30–40 MJ/kg, which offsets fossil fuel displacement while reducing landfill volume by up to 90%. However, compared to mechanical recycling, incineration exhibits higher lifecycle greenhouse gas emissions (by 1–2 tons CO2e per ton in modeled scenarios) and increased acidification from flue gas treatments, though it avoids recycling's preprocessing losses where only 50–70% of collected plastics yield usable material. Real-world recycling inefficiencies, including contamination rates exceeding 20% in mixed streams, can erode these advantages, making incineration a more consistent option for unsortable waste. Landfilling plastics demands minimal upfront energy—primarily for and compaction— with U.S. tipping fees averaging $54 per in , far below the $100+ per for sorting and reprocessing. Plastics' inert nature prevents , limiting direct contributions (estimated at <1% of ), unlike organics; modern U.S. landfills capture 75% of , yielding net GHG impacts 20–50% lower than uncaptured scenarios. A strategy of directing all U.S. plastic waste to such modern sanitary landfills, equipped with liners, leachate collection, and gas capture, could virtually eliminate domestic mismanagement and export-related pollution leakage. However, this would accelerate landfill capacity use, forgo resource recovery, and maintain reliance on virgin production. Lifecycle analyses consistently show reduces global warming potential by 0.5–3 CO2e per versus landfilling, but this assumes closed-loop recovery; globally, with 79% of historic landfilled and at 9%, the system's low yield often results in higher cumulative emissions from redundant collection efforts. Reduction strategies eclipse recycling by preempting waste generation, as evidenced by the EU's 2021 Single-Use Plastics Directive banning items like and straws, which achieved 20–30% consumption drops in compliant sectors by 2023 through substitution, outpacing 's <10% diversion for similar disposables. These bans target root causes, avoiding the full chain of production and end-of-life impacts, whereas diverts only a fraction while incurring sorting (up to 10–20% of savings) and downgrading that necessitates additional virgin inputs. Debates on plastic waste management suggest that enhanced landfilling, paired with export restrictions and upstream reductions such as single-use bans or extended producer responsibility, may offer superior containment compared to low-efficiency recycling systems vulnerable to leakage, though experts stress that reducing overall production is paramount over end-of-life approaches alone. Empirical data indicate reductions via yield 2–4 times greater avoidance per invested resource than expansions, aligning with causal priorities of minimizing throughput over recovery. Virgin plastic production from or often exhibits lower lifecycle impacts than recycled counterparts in inefficient systems, with polyethylene's footprint at 1.5–2 kg CO2e/kg versus recycled variants reaching 2–3 kg CO2e/kg when factoring global transport, (20–50 MJ/kg), and yield losses up to 30%. High-efficiency narrows this gap, saving 50–80% over virgin, but prevalent low-grade processes—yielding downcycled products requiring blending with 50% virgin —undermine net benefits, rendering virgin feedstock from abundant hydrocarbons a baseline less burdened by secondary inefficiencies. This underscores reduction's primacy, as both virgin and recycled pathways embed upstream emissions unavoidable in use-phase demands.

Criticisms and Controversies

Industry Knowledge of Ineffectiveness

In April 1973, a report presented to executives concluded that plastics on a broad scale was unlikely due to material degradation, high costs, and the infeasibility of sorting diverse types. Later that year, a memo from the Society of the , the sector's lobbying group, similarly highlighted fundamental barriers to achieving more than minimal rates. In May 1974, president Charles Brelsford McCoy stated in a letter to the Great America Foundation that once plastic components were blended into products, them was precluded, rendering 's participation "not feasible." That same year, an industry insider remarked during a speech that there was "serious doubt" could ever be economically viable. These assessments reflected a consensus that feasibility would remain below 10 percent, given technical and economic constraints. Despite this foreknowledge, the industry pivoted in the late 1970s and 1980s to aggressively promote as a comprehensive solution, coinciding with heightened public scrutiny of plastic waste following the and oil crises, which amplified concerns over resource scarcity and disposal. Major producers including Exxon, Chevron, Dow, and funded ad campaigns totaling over $50 million annually by the late 1980s, emphasizing plastic's recyclability to sustain consumer acceptance and market growth. This promotional effort, which exceeded $30 million in cumulative spending through subsequent decades for recycling-specific messaging, positioned the process as an alternative to waste reduction, even as internal documents acknowledged its limited scalability. The strategic intent, as revealed in industry documents and executive admissions, was to forestall regulatory threats such as mandatory deposit-return systems (bottle bills) or caps on virgin plastic production, which could have curtailed sales volumes. Former Society of the Plastics Industry president Larry Thomas acknowledged that recycling advocacy aimed to "keep selling more plastic" rather than genuinely address waste, allowing producers to expand output without confronting disposal limits. By 1989, this included lobbying in nearly 40 states to require recycling symbols on packaging, fostering an illusion of viability to undermine calls for bans on non-recyclable plastics. Investigations by and Frontline, drawing on declassified memos, confirm this approach preserved industry profits by deflecting toward voluntary, low-efficacy measures over enforceable restrictions.

Greenwashing and Public Misinformation

Proponents of "advanced recycling" technologies, such as , have promoted these methods as scalable solutions to plastic waste, despite indicating severe limitations in yield and economic viability. A 2024 investigation by revealed that pyrolysis processes typically convert only 15-20 pounds of reusable plastic from an initial 100 pounds of input waste, with scalability challenges preventing widespread adoption and actual diversion from landfills or incinerators. Nevertheless, the (ACC), representing chemical manufacturers, has lobbied aggressively for state-level to mandate or incentivize advanced recycling, achieving passage in 25 states by March 2024, including Wyoming's bipartisan bill that modernizes infrastructure under the guise of pollution reduction. This advocacy persists amid data showing that such technologies often produce outputs more akin to feedstocks than high-quality recycled plastics, effectively extending production rather than closing material loops. The universal —known as the "chasing arrows"—has contributed to widespread consumer deception by implying recyclability for items that are not feasibly processed in practice. Surveys indicate significant confusion: a 2024 poll found that 62% of U.S. voters strongly agreed that affixing the symbol to non-recyclable plastics is deceptive, reflecting how it encourages improper disposal and contaminates waste streams. Similarly, 68% of Americans in a 2019 study believed that any item bearing the symbol or could be curbside recycled, leading to over-recycling efforts that burden municipal systems without proportional environmental gains. These symbols, originally intended to guide sorting, now function as marketing tools that obscure the reality that only about 9% of all plastics ever produced have been recycled globally, per material flow analyses. Public education campaigns and media narratives often perpetuate the illusion of effective , sidelining causal economic barriers like virgin material's lower cost. Despite lifecycle assessments demonstrating that rates remain below 10% in the U.S. due to market disincentives, outlets have historically amplified industry claims of progress without rigorous scrutiny of scalability or net emissions. This normalization ignores first-order realities, such as the persistence of low yields in advanced methods, fostering overconfidence in as a panacea while underemphasizing reduction or alternative . Industry-backed messaging, echoed in some coverage, thus sustains greenwashing by framing marginal innovations as transformative, even as empirical data from 2024 reports underscore their inadequacy for systemic change.

Policy and Systemic Failures

Government policies mandating plastic recycling, such as (EPR) schemes, have frequently resulted in low actual diversion rates despite fee collection from producers, subsidizing collection systems that fail to achieve meaningful material recovery. In , the SB 54 EPR law, implemented with producer fees starting in 2025, targets 30% recycling of plastic by 2028, yet a 2024 mandated study revealed 8.5 million tons of covered entered landfills that year, indicating persistent high disposal rates and limited immediate impact on recycling . These programs often overlook processing bottlenecks, leading to unintended boosts in waste exports as domestic systems prove inadequate; following China's 2018 import ban on most plastic waste, exporting nations faced overloaded receiving countries, with global plastic waste trade collapsing and redirecting low-value recyclables to lower-capacity destinations rather than enhancing local capabilities. In the UK, legislative loopholes as of 2025 continue to incentivize plastic waste collectors to export materials overseas for minimal processing instead of investing in viable domestic recycling, exacerbating "waste colonialism" without reducing overall production or pollution. International agreements, including the U.S. Plastics Pact's alignment with global commitments to recycle or 50% of plastic packaging by 2025, have gone unmet according to 2024-2025 self-reports, with participants far short on targets despite progress in reforms, highlighting gaps and overreliance on voluntary pledges. Subsidies for virgin plastic production, estimated in the billions annually from incentives, distort market signals by undercutting recycled material economics, thereby diminishing incentives for producers to prioritize reduction or closed-loop systems over continued reliance on cheap, subsidized feedstocks. This systemic favoritism toward perpetuates inefficiencies, as policies emphasize mandates without addressing upstream economics that render downstream recovery uncompetitive.

Future Outlook

Emerging Technological Innovations

Recent pilots in AI-assisted sorting technologies, particularly those integrating , have demonstrated potential to enhance waste separation by identifying material compositions with greater precision than traditional methods. In 2025, systems deployed by companies like Specim and UCY Technologies utilized hyperspectral cameras combined with AI algorithms to accelerate sorting speeds and improve accuracy, enabling differentiation of based on spectral signatures even when contaminated or mixed. These advancements address key limitations in mechanical , where reduces output purity; AI-driven approaches have been reported to lower rates by up to 85%, yielding higher-quality recyclates suitable for food-grade applications. The global market for such technologies in material sorting is projected to reach $1.5 billion by 2025, reflecting growing adoption in facilities. Enzymatic depolymerization represents another frontier, targeting chemical recycling of specific polymers like polyethylene terephthalate (PET) through bio-catalytic breakdown into monomers for repolymerization. Carbios, a leader in this area, broke ground in April 2024 on its first industrial-scale PET biorecycling plant in Longlaville, France, designed to process 50,000 tons annually using proprietary enzymes that achieve up to 90% depolymerization in 10 hours. By July 2024, Carbios signed agreements to deploy similar technology in China via a partnership with Zhink Group, aiming for another facility handling over 50,000 tons yearly. However, these initiatives remain largely at pilot or early construction stages, with Carbios revising its French plant timeline to 2026 amid financial and operational challenges, highlighting persistent high enzyme production costs and energy demands that limit economic viability. Despite these innovations, scalability hurdles persist, as evidenced by Lux Research's 2025 analysis of advanced , which notes repeated missed milestones and regulatory setbacks constraining commercial deployment. Policy uncertainties, including varying classifications of enzymatic processes under waste regulations, have delayed projects and increased compliance costs, underscoring that while lab-scale efficiencies are promising, full-scale integration requires overcoming infrastructural and economic barriers to achieve widespread impact.

Realistic Alternatives and Reforms

Policies prioritizing waste reduction at the source, such as bans on single-use plastic bags and bottles, have demonstrated superior empirical outcomes to recycling programs in curtailing volumes. As of , 91 countries and territories have enacted full or partial bans on s, with documented reductions in bag litter comprising 25% to 47% of shoreline cleanup items post-implementation. In , the 2017 ban resulted in 80% of the population ceasing use within years, while U.S. examples like showed 48% and 76% drops in residential and commercial , respectively. These measures achieve 30-50% reductions in targeted items by altering consumer behavior and supply, outperforming global rates, which remain below 10%. Waste-to-energy (WTE) incineration represents a viable disposal alternative, particularly for non-recyclable plastics, by diverting waste from landfills while generating energy offsets. Japan processes approximately 75-79% of its municipal solid waste via incineration as of fiscal year 2023, reducing landfill reliance to under 2% and producing electricity equivalent to powering millions of households through heat recovery systems. Lifecycle assessments indicate WTE can yield lower net emissions than landfilling for mixed plastics, as methane avoidance and energy substitution compensate for combustion outputs, though outcomes vary by plant efficiency and local grid decarbonization. Reforms to internalize externalities through market mechanisms include terminating distortive subsidies and imposing full producer liability. Fossil fuel subsidies, estimated to exceed $500 billion annually globally, artificially lower virgin plastic costs by 20-30%, undermining recycling incentives; eliminating them would align prices with true environmental costs. (EPR) frameworks, via product-specific fees funding collection and disposal, have boosted plastic recovery rates by 20-50% in implementing regions by shifting liability upstream. should further mandate decisions based on site-specific lifecycle analyses, favoring virgin production where empirical data—such as energy-intensive recycling yielding higher emissions than efficient virgin processes—demonstrates net benefits, ensuring causal over mandated .

References

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