Circularizing Rigid Plastics: How AI, Machine Learning, and Biotechnology Are Changing the Market

The upcoming UN Global Plastic Treaty negotiations in November highlight the tension between nations advocating for production caps, such as those in the "High Ambition Coalition" (including the US and EU countries), and petrochemical-producing regions like the Middle East and Asia. While some view production limits as a betrayal, many emphasize the importance of recycling. Despite ongoing debates, global production of plastics remains significant, with 390 million tons produced in 2021 according to industry estimates.

Experts from various sectors discuss the latest advancements in recycling, including the integration of AI, the shift to monomaterials, and the future of bioplastics, all within the context of evolving global regulations.

AI in Sortation Technology

A major breakthrough in recycling technology has been the introduction of AI and machine learning. One company that has been at the forefront of this is currently moving away from marker-based sorting systems, transitioning towards AI-based technology. Initially, marker technology allowed for efficient sorting of mixed plastic packaging, but it required changes to product labeling, which faced slow adoption by brands. However, recent AI developments have transformed the field.

The company's collaboration with Tomra on sorting trials using near-infrared and visual spectrometry, combined with deep-learning technology, has led to impressive results. During these trials, their system processed 5 tons of mixed plastic waste per hour and achieved 97% purity in sorting food-grade packaging. This success paves the way for expanding AI-driven sorting solutions in the recycling of rigid plastics, particularly for food-grade polypropylene (PP).

Monomaterials for Easier Recycling

Another major development in the circularization of rigid plastics has been the creation of monomaterial PP products. These materials, which have properties similar to virgin polymers, are easier to recycle on a large scale and maintain quality through multiple recycling cycles. Recent trials incorporating 30% recycled content into packaging demonstrated no loss in quality compared to virgin materials, showcasing the potential of monomaterials to revolutionize rigid plastic recycling.

The key challenges to scaling this technology include:

1. Mobilizing regulatory bodies to approve novel recycling technologies for plastics beyond PET.

2. Redesigning post-consumer packaging for easier recyclability.

3. Increasing the collection of post-consumer packaging to boost available feedstocks for recycling.

Addressing Fluctuations in the Recycled Plastics Market

One ongoing issue in expanding the use of recycled materials is the fluctuating availability and cost of recyclates. Companies are working hard to secure reliable sources of recycled plastics, and progress in technology and partnerships has been made. However, balancing profitability with environmental goals remains a challenge as the industry shifts towards a circular economy.

The Role of Bioplastics in Circularity

Bioplastics, such as polylactic acid (PLA), have been promoted as potential solutions to the plastic waste crisis. These materials, derived from renewable feedstocks like sugarcane, offer a lower carbon footprint than traditional plastics. The market for bioplastics is expected to grow substantially, with predictions of reaching $16.8 billion by 2034. However, skepticism remains regarding their scalability, with some experts questioning the feasibility of widespread adoption due to challenges in composting infrastructure and concerns over cost competitiveness.

Despite these concerns, proponents of bioplastics argue that better consumer education and supportive legislation could accelerate their adoption. With a significant reduction in carbon footprint compared to conventional plastics, bioplastics have the potential to play a central role in the future of the industry.

As AI, machine learning, and biotechnology continue to reshape the recycling landscape, the market for rigid plastics is evolving rapidly. The integration of innovative technologies into recycling systems, the development of monomaterials, and the potential of bioplastics all represent crucial steps toward a more circular, sustainable plastics economy.