In an age of growing environmental awareness and a pressing need for sustainability-which is something we at Packstyle have always shared-the recyclability of plastic materials plays a crucial role. The practice of regenerating these materials has multiple positive impacts on the environment. For example, recycling contributes to the reduction of landfill waste, influences the saving of primary resources, and reduces energy consumption and greenhouse gas emissions. 

Plastic: can it be sustainable?

In recent years, plastics have often been demonized because of their negative environmental impact; witness the photos and videos we are exposed to, showing us portions of the oceans covered with garbage or endless landfills. However, it is important to recognize that, if properly managed and recycled, plastic can have a lighter environmental impact than other materials, turning from waste into a resource. 

With regard to flexible packaging-we discussed this in our previous article (Plastics and sustainability in flexible packaging between falsehoods and truths (packstyle.com)) - , the Life Cycle Assessment (LCA) analysis, i.e., the entire life cycle of packaging, shows that compared to other types of packaging, CO2 emissions during production, transport and disposal are very small. For this reason, we can say that Packstyle pouches start with an advantage due to their nature: they are lightweight packaging that takes up little space and therefore, compared to other types of packaging, are more sustainable.

A next step in the proper management of plastics is their ability to be recycled. Recyclable plastics can be made into new products, reducing the need to produce virgin plastics and thereby decreasing the consumption of natural resources and energy required for production. Therefore, when plastics are designed to be recyclable and are effectively recycled, they can be a more sustainable solution, contributing to a circular economy and reducing the overall environmental impact. To ensure that a plastic product is recyclable, it is essential that it is carefully designed from the initial stage. The design must consider several key factors: the use of monomaterials or compatible with each other, the ease of separating components, and the absence of contaminants that can complicate the recycling process.

The importance of sustainability at Packstyle

In the field of sustainability, at Packstyle, we never stop. We study solutions that can decrease our environmental footprint, improving our performance and our products. Over the years we have introduced more and more environmentally conscious proposals, such as recyclable paper packaging, with Aticelca certification, which guarantees that it can be disposed of in waste paper, and metallized or transparent film solutions that are also recyclable. Regarding the latter two products mentioned above, Packstyle has resorted to Interseroh+ certification, an internationally recognized German body that subjects packaging to strict evaluation of the materials used. The choice of adhesives and inks also goes in the direction of sustainability: Packstyle packaging, being suitable for food contact, consists of materials and adhesives that are absolutely not harmful to humans and also to the environment.

The ultimate test: the CSI test

Designing and producing packaging with recyclable and sustainable materials is therefore among the main goals set by Packstyle, but once again, we did not stop at this goal and decided to look and move forward in the direction of sustainability, verifying empirically that our materials are indeed recyclable, despite the certifications.

For this reason we chose to rely on CSI, a European reference hub for verification and certification of compliance of materials, products, plants and companies, which shares with us at Packstyle the goals of safety, quality and environmental sustainability.

Our curiosity and desire to understand the complex process behind the recyclability of a material was satisfied thanks to CSI, which reproduced with one of our packaging samples an entire recycling process based on the EN 13430 standard on recyclability of packaging.

The recyclability test was supported on the two new Packstyle materials: recyclable transparent film and recyclable metallized film. For the reproduced recyclability cycle to match the real one, finished Packstyle pouches were provided to the CSI. For both tests, Packstyle pouches of size 26x31+10 cm, weighing 23 g, printed with custom graphics and equipped with a resealable PP zipper were chosen, in one case in recyclable transparent film, in the other case in recyclable metallized film.

The first phase of the investigation found that both materials supplied by Packstyle matched PP monomaterials, suitable for food contact and free of elements not allowed by current waste and packaging legislation.

At the next stage, the two different samples, one in transparent film and the other in metalized film, were subjected to grinding. According to the CSI, no structural changes in the materials as a result of friction or overheating were evident at this stage of the process. Both the transparent film and the metalized Packstyle film, despite being subjected to friction and high temperatures, did not change their nature. The next step was washing, rinsing and drying. Also in this section of the process, no structural changes were detected in the samples, which remained in the form of coupled flexible film fragments. In addition, no residues due to coupling adhesives, inks, or surface treatments were found. In fact, Packstyle has always used only non-harmful water-based adhesives so that its packaging can be suitable for preserving even the most delicate products, such as food or cosmetics, without altering their taste, texture or formulation.

After the two samples were ground, washed and dried, the material was extruded by a special screw extruder, and even at this stage, in both tests the CSI did not detect any critical or undesirable phenomena. The final fragments were shiny and smooth on the surface.

Packstyle packaging then, once sorted, ground, washed and extruded, was transformed into PP granules, ready to be used again for recycled plastic production. The entire process recreated in the CSI laboratories then confirmed compliance with technical standards on the recyclability of the transparent film and recyclable metallized film with which Packstyle flat pouches and doypacks are produced.

Secondary raw materials: resources for the circular economy

Secondary raw materials from recycling, since they are not extracted directly from nature like primary raw materials, are fed back into production processes, helping to create a circular economy in which materials are continuously reused. Packstyle recyclable film pouches, by transforming into PP fragments, are also a valuable resource for promoting environmental, economic and social sustainability, reducing reliance on natural resources and minimizing the environmental impact of human activities. With CSI, we got to the heart of the recycling process, verified the individual steps to state with certainty that transparent and metallized PP monomaterial packaging can be effectively recycled and used as a secondary raw material in sectors such as: giftware, automotive, outdoor, home and garden. Our mission toward ever-higher levels of sustainability has reached another important milestone, but we know that Packstyle does not stop and continues its search toward solutions that are mindful of the well-being of individuals and the environment.

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