Circular Plastics Economy

Plastic production is energy-intensive. The vast majority of plastic is derived from fossil fuels (oil and gas). The production process contributes significantly to global GHG emissions. The typical emissions intensity is approximately 2.5 to 3.0 metric tons of CO₂ per metric ton of plastics produced.²

Most plastics do not biodegrade; they photodegrade into microplastics, which persist in the environment for centuries. However, this also means that plastic is durable. Its lightweight nature means that plastic components reduce the fuel consumption and carbon emissions of vehicles and aircraft.

The ideal solution would be to rethink the way plastic is produced by: 

• Accelerating the design and development of new polymers that are more recyclable
• Redesigning product packaging to become more sustainable and reusable

Instead of relying on virgin plastic, plastic packaging can incorporate more post-consumer recycled (PCR) materials in the manufacturing process. This can happen at the design stage by utilizing advanced modeling and simulation capabilities to optimize packaging designs and increase the proportion of PCR materials. This can result in more lightweight packaging and reduced overall material use without compromising product performance.

By implementing this approach, a consumer goods manufacturer created sustainable packaging solutions that used up to 18% less material per bottle while incorporating up to 76% PCR materials into the manufacturing process.

Companies can reduce the use of plastics by redesigning packaging systems to reduce waste, improve recyclability and increase the use of recycled or renewable materials. Instead of following a linear 'take-make-dispose' model, companies can create packaging systems that keep materials in use for longer and support circular economy goals.

Some key approaches include:

• Reducing material usage through lightweight packaging design
• Designing packaging for recyclability using mono-material structures
• Implementing reuse or refill models for packaging where possible
• Utilizing advanced modeling and simulation to optimize packaging development, material use and product performance before production
• Improving material recovery systems and working with partners across the supply chain

The core principles of the circular economy are to eliminate waste, circulate products and materials at their highest value, rethink plastic use and regenerate nature. When it comes to plastic waste, the circular economy approach would be to extend its usefulness beyond the product's single-use nature. Some examples include: 

• Converting plastic waste into useful products such as toys and bags
• Mixing shredded plastic into concrete mixtures to improve the compressive strength of the structure
• Converting plastics into filaments for 3D printing

In addition to PET, other types of recyclable plastic include HDPE (high-density polyethylene), PVC (polyvinyl chloride), LDPE (low-density polyethylene), PP (polypropylene), PS (polystyrene) and other resins. However, it's crucial to recognize that not all plastics are recyclable and certain types may even pose hazards. In some instances, plastics may not be the only solution available.

Plastics are both a challenge and an opportunity in a circular economy due to their durability and persistence. They improve resource efficiency by reducing weight, energy use and waste, especially in packaging and transportation.

Many types of plastics are recyclable, with growing potential through both mechanical and chemical recycling methods. Plastics also enable circular business models such as reuse systems and closed-loop manufacturing.

However, recycling rates remain low due to issues with collection, sorting, contamination and cost. Because many of these plastics may have distinct value chains, it is difficult to generalize about the decarbonization and circularity of plastics. That's why designing plastics for circularity from the get-go is critical.