BO-PET films with PCR content

Meaning of the term PCR

The abbreviation PCR stands for “post-consumer recycling” or “post-consumer recyclate” and refers to recycled materials that have already been used and disposed of by consumers and subsequently collected. This is distinct from PIR (“post-industrial recyclate”), which refers to materials generated as waste during industrial production processes. The term pre-consumer recycling is also used for this type of industrial material, but to avoid confusion with PCR, the abbreviation PIR has become standard.

Recycling of PIR materials has long been recognized by industry as an economic necessity, independent of environmental or sustainability considerations. It is simply cost-effective to reintegrate pure production residues into the manufacturing process. PCR, however, is far more complex. The material must be collected, sorted by type, and cleaned before it can be reintroduced into production. This involves risks and costs that must be financed.

BO-PET films with PCR content

Recyclates can be processed in production, but they do not have exactly the same properties as virgin materials derived from petrochemical sources. Producing BO-PET films with PCR content is therefore not as simple as melting down PCR material and converting it directly into new film.

PET bottles provide a successful example of recycling and reuse. In Germany, the recycling rate for PET bottles is around 90 percent, and bottles containing up to 90 percent PCR material are already on the market. One manufacturer has even introduced a bottle made from 100 percent PCR material.

Film production is more complex, but research is ongoing to increase the PCR content in films. To date, BO-PET films with a PCR content of approximately 50 percent have been successfully produced.

Applications of BO-PET films with PCR content

• Environmentally friendly food packaging
• Sustainable packaging for non-food consumer goods
• Products and packaging for brands with sustainability certifications
• Technical applications with a focus on recycling

Challenges in collecting plastics for BO-PET films with PCR content

Post-consumer plastic waste is not sorted by type and must therefore be separated before recycling. This applies regardless of whether the waste originates from household collection systems, commercial waste streams, or mixed production waste.

Automated separation technologies have been developed for mixed plastic waste. Near-infrared (NIR) technology can now separate different types of plastics in automated sorting facilities. These processes can achieve purity levels of up to 98 percent. PET fractions separated in this way can then be directed into recycling streams. Automated sorting enables high-quality and cost-effective material recovery.

Special challenge: PET materials from shoes and textiles

Recycling PET from textiles or footwear is particularly demanding. Mixed fabrics containing different plastic types or natural fibers cannot easily be separated to recover PET. Only when mechanical separation is possible, for example in footwear, can PET components be isolated and subsequently sorted by NIR technology. The recovered PET fraction can then be recycled. Some companies are experimenting with take-back systems for textiles and footwear, but the long-term effectiveness of these initiatives remains uncertain.

Further processing of recycled PET into BO-PET films with PCR content

Collected and sorted PET materials are cleaned and shredded into small flakes or pellets. When melted, they form recycled PET (R-PET). According to current technology, up to 90 percent R-PET can be used in the production of BO-PET films. However, R-PET may contain both PCR and PIR material.

Increasing the PCR share in BO-PET film production is the focus of numerous research projects. During melting and extrusion, conventional petrochemical PET is blended with recycled PET to form new thin film webs. These are then stretched longitudinally and transversely to produce BO-PET films with PCR content.

Through coextrusion with other plastics or the addition of specific additives, BO-PET films with PCR content can be tailored to meet the requirements of end-use applications.

Advantages of BO-PET films with PCR content

• Improved environmental performance due to reduced use of fossil resources
• Lower energy and water consumption compared to production from virgin petrochemical materials
• Recyclability, allowing films to re-enter the recycling loop
• No downcycling effect; instead, a closed-loop system that reduces environmental impact reduced waste sent to incineration plants or landfills
• PET has minimal absorption of foreign substances, enabling BO-PET films with PCR content to be used in food packaging

Innovative technical approaches

Enzymatic depolymerization of PET products is currently being explored in various research projects. This method aims to recover monomers from PCR materials for reuse in the production of new PET products. Since these recovered raw materials are chemically identical to those derived from petroleum, it would theoretically allow the production of BO-PET films made from 100 percent PCR material.

Initial laboratory-scale successes offer promising prospects for achieving higher recycling rates. This method could improve recycling not only for PET bottles but also for textiles, films, and footwear.

Enhancing sustainability

Some research projects aim to increase the recycled content in polyester film production. Another approach to improving the environmental footprint of PET films is the use of renewable raw materials for producing the base monomers. However, even PET produced from renewable sources should ideally be integrated into recycling systems, as recycling consumes less energy and water and reduces waste.

BO-PET films with PCR content will therefore remain relevant even if PET is eventually produced entirely from renewable raw materials.

Changing regulatory frameworks

In addition to technical and quality challenges, regulatory, economic, and market-specific factors are continuously reshaping the framework for BO-PET films with PCR content. Legislation at national and especially European levels acts as a catalyst for change.

The EU Packaging Regulation and corresponding national laws set binding targets for reducing packaging waste and increasing recycling rates. Manufacturers, converters, and distributors are under increasing pressure to use recyclable materials. For PET packaging, a measurable and rising share of PCR content is required. BO-PET films with defined PCR content meet these requirements. They offer high performance, versatility, and seamless integration into existing recycling systems.

Economic considerations

Growing demand from businesses and end consumers is another driving factor. Sustainability is no longer a niche concern but a central purchasing criterion, particularly in premium brand segments. Packaging made from BO-PET films with PCR content enables companies to visibly communicate their environmental goals.

At the same time, such films must meet the highest standards in terms of transparency, barrier properties, printability, and mechanical strength. Film manufacturers must strike a balance between ecological responsibility and technical performance to succeed in the market.

Raw materials for BO-PET films with PCR content

The availability of high-quality PCR raw materials depends on collection volumes and quality. This works very well for PET bottles in Germany. For film waste, recycling methods must be further optimized to improve recyclate quality. Only then can a stable PCR supply be ensured at competitive prices relative to virgin petrochemical raw materials.

In the long term, improved collection systems, higher recycling rates, and increasing production volumes are expected to create economies of scale, making BO-PET films with PCR content even more competitive.

Design for recycling as a driver

The “design for recycling” approach supports efforts to increase PCR usage. Packaging and products are designed to be easily sortable and recyclable at the end of their lifecycle. Monomaterial solutions, reduced color schemes, and the avoidance of disruptive additives and composite materials facilitate the reintegration of BO-PET films with PCR content into material cycles.

This enables the creation of more closed-loop systems and improves recyclate quality.

In the long term, BO-PET films with PCR content will contribute to reducing plastic waste and conserving fossil resources. They represent an important building block in the transformation of the plastics industry toward greater sustainability.

FAQ