Many grow up learning about the three Rs of recycling: reduce, reuse, and recycle. While the three Rs are still at the core of the recycling industry, it takes more than a clever catchphrase to sustain the circular economy. Through advanced research and development (R&D), we’ve reimagined the possibilities of recycled materials to build a more sustainable future.

As environmental awareness grows, businesses are adopting more eco-friendly practices to address consumers’ demands for sustainable products and packaging. Additionally, new state-level PCR (post-consumer resin) content mandates continue to be introduced, adding a sense of urgency to corporate sustainability initiatives. But, with the U.S. currently posting a recycling rate of approximately 32%, the national supply of recycled plastic won’t be enough to meet the rising demand for rPET. This supply shortcoming makes innovative R&D processes even more crucial.

The Role of R&D in the Plastic Recycling Process

Ongoing research and development make it possible to streamline recycling processes and continually improve the sustainable products they produce. Having efficient processes in place is essential to meeting consumers' demands and legal requirements. For companies that operate in states that do not yet impose PCR content mandates, investing in R&D can still be a strategic way to stay ahead of the regulatory curve and prepare for future changes.

Adding recycled content to a company’s products and packaging is certainly easier said than done. Products need to be more than sustainable — they need to work. Without the benefit of R&D, companies risk damaging the quality of their product offerings and, thus, their reputation with consumers and partner companies. 

Take food products, for example. Packaging needs to meet a rigorous set of standards to be FDA-approved and safe for direct contact with food. It also needs to preserve the quality of the food to give it the most extended shelf life possible. Thanks to R&D, sustainable rPET packaging solutions have been created to meet standards that were previously only available with vPET applications. As a result, businesses that utilize rPET packaging can keep food fresh, reduce packaging waste, and contribute to the zero-waste economy.

Recycling R&D Explores Possibilities & Supports Proven Methods

Research and development play a role in every aspect of the circular economy, from waste collection to final application. However, even the most promising advancements are not without their challenges. As researchers and material scientists continue looking for ways to meet the growing demand for recycled materials, they must compare the proposed benefits of new technologies with the efficacy of time-tested methods. Nowhere is this more evident than in the current debate between chemical and mechanical recycling processes.

With chemical recycling, recycled materials are broken down into their building blocks. While this method is often praised for the purity of the recycled content it produces, the current process is not scalable or sustainable. It’s also costly. So, while it may be touted as the up-and-coming method of choice, chemical recycling is currently not a competitive alternative. 

Mechanical recycling, in which post-consumer plastic is thoroughly cleaned, dried, and ground to produce PET flakes that are converted to rPET pellets via an extrusion process, remains the tried-and-true method trusted by leading rPET producers like Verdeco. While it may require more precise sorting of recycled plastics, it has been proven to work on a larger scale and is commercially available.

Verdeco’s R&D Approach

At Verdeco, we use advanced research and development to drive innovation forward. With three state-of-the-art facilities strategically positioned across the United States — including our Innovation Center in Greenville, South Carolina — our cutting-edge technology, in-house R&D, and best-in-class production facilities enable us to collaborate with companies and ensure a reliable supply of customized rPET pellets.

Through in-house testing, analysis, and small-scale production, our R&D team develops proprietary methods to convert PET flakes into custom rPET pellets, adding value and functionality to the post-consumer plastic. This material science approach enables our scientists to create rPET pellets that meet our customers’ quality standards, product requirements, and application needs.

Our commitment to quality and innovation can be seen throughout our entire process, which we continuously monitor and improve to deliver industry-leading solutions that meet the evolving needs of our clients and the customers they serve.

Ready to get started on your own customized rPET? Contact us today!