1. Who is Sonoco and what are you focused on?

Sonoco is a South Carolina-based global packaging company with more than 20 mills worldwide. Among our packaging products, we manufacture rigid paper cans, steel cans, thermoformed plastics and other packaging formats. Sonoco is uniquely positioned as a leading recycler, paper mill operator and paper packaging converter, in addition to other formats, to help push the industry to look towards future innovations and grow end-of-life solutions across the entire paper value chain.

2. How do you typically approach recycling of new products at your mills?

After validating that our mills could recycle rigid paper cans in residential mixed paper, we decided to further demonstrate the ability to recycle other similar polycoated fiber-based containers through the post-consumer mixed paper stream.

3. Where do you currently accept paper cups?

Hartsville, South Carolina. and we are exploring other Sonoco mills as well that use residential mixed paper.

4. What are some of the steps you took to determine that accepting cups wouldn’t create new challenges for your mill?

With support from the NextGen Consortium, we conducted two main activities to assess how cups might behave. First, we conducted lab-based testing of both single- and double-sided poly-coated fiber cups. Second, and after we were confident that the cups would not pose any issues to our equipment, we ran a large-scale trial whereby we dosed in nearly 20 tons of cupstock and cups into our pulper alongside other mixed paper, increasing the volume relative to other materials to test the system and upper bounds of materials we’d anticipate receiving if we accepted cups. Based on those results we felt confident that cups could be included in our accepted materials list and we were thrilled to have the mill listed alongside others on Foodservice Packaging Institute’s end market map of mills that accept cups.

5. What about your other paper mills?

Before we broadly accept cups at more of our mills, we’d want to distill our findings from the Hartsville location and consider any additional steps those mills would need to take to feel confident in accepting cups. This might include additional lab-and mill-based trials.

6. Any advice you’d give to other mills considering including cups?

Every mill is slightly different, from their equipment to operating conditions to inbound material mix. Testing to those conditions is a key proof point in determining what might work best in that location.

7. What’s next for Sonoco in its efforts to improve polycoated paper recycling?

Sonoco is a founding member of the Polycoated Paper Alliance that kicked-off in March 2023, which aims to increase widespread end-market acceptance of polycoated paper packaging products. We are collaborating with like-minded member brands and industry leaders on developing improved and harmonized data, updated design guidelines, expanded end market acceptance and upgraded mill specifications, among other initiatives.  

Behind the walls of recycling facilities across the U.S., a sea of materials moves through hands and machines working hard to get them to the end of the line––and the beginning of their next life. A critical balance of manual labor and automation enables the sorting and recovery of these materials in a closed loop system. Yet despite a multi-step sortation process, it is difficult to track what flows through the system at all times. It’s a challenge that results in many recycled materials losing potential value, in addition to millions of dollars worth of valuable material being sent to landfill unintentionally.

Among the diverse materials flowing through the recycling system are the yogurt containers, and iced coffee and fountain beverage cups many of us use on a regular basis. These are just a few examples of products made of one of the most commonly used resins in foodservice packaging today: polypropylene (PP). PP is a valuable material that should be kept in circulation to reduce waste and meet corporate commitments to use more recycled content in foodservice packaging. With that said, very little mechanically recycled food-grade PP actually cycles back into food-grade applications. Most end up in nonfood-grade applications that limit their value and the number of times they can be reused. To create a more circular path for food-grade PP, we must first answer the question: what is in the PP stream today, and how much of it is food-grade or clear food-grade PP?

The NextGen Consortium is a multi-year industry collaboration addressing single-use foodservice packaging waste by advancing solutions across material innovation, reuse and recovery infrastructure––and it’s working to answer that question. In the fall of 2022, the Consortium partnered with Resource Recycling Systems to examine PP bales in two materials recovery facilities (MRFs) to learn what was inside. While only a snapshot in time, the results were enlightening.

On average, nearly half of the PP bales (48%) were presumed food-grade, and more than a quarter of the bales were clear food-grade (26%). Clear beverage cups represented 14% of the bale on average. The high percentage of food-grade PP suggested that there is untapped value in the PP stream. A better system is required to ensure food-grade and/or clear food-grade PP is properly sorted into a separate bale at some point in the value chain if we are to retain its highest potential value.

This year, the NextGen Consortium is diving even deeper, launching a first-of-its-kind study leveraging artificial intelligence (AI) to analyze the composition of the PP material stream well before it ends up in a bale. Together with its managing partner––Closed Loop Partners’ Center for the Circular Economy––the NextGen Consortium is working with Greyparrot, a leading AI waste analytics platform for the circular economy. The collaboration aims to track and categorize objects in the PP stream, and determine the volume of valuable food-grade material passing through the system. AI is on the rise as one potential means of increasing visibility into the recycling process. Today, more technologies are needed to handle an increasingly mixed stream of collected materials, including plastics, electronics, textiles and food scraps––and to enable the recovery of clean, high-quality materials.

“Ensuring that recovery infrastructure can keep pace with a rapidly growing and diverse material stream is critical to advancing the circular economy, alongside solutions such as material innovation, reduction and reuse,” said Kate Daly, Managing Director and Head of the Center for the Circular Economy at Closed Loop Partners. “An important part of our work in the NextGen Consortium is identifying opportunities for data collection and analysis that can advance the circularity of foodservice packaging, and drive greater value for stakeholders across the system, including brands, innovators, infrastructure operators and consumers.”

As part of this project, the Greyparrot Analyser units will be installed above the PP recovery conveyor belts at four leading U.S. MRFs: Balcones Recycling, TX; Cougles Recycling, PA; Rumpke Recycling, OH; and Eureka Recycling, MN. Greyparrot’s AI-powered computer vision system uses cameras to capture images of objects in the PP stream, aiming to quantify and qualify the materials flowing through the MRFs. Their AI model will look to categorize each object based on material, format, financial value and brand, as well as distinguish food- and nonfood-grade material, using those images. Their units will then send that data to an analytics dashboard in real-time. Through machine learning, the flexible vision systems can help improve their package recognition and classification over time.

“We use artificial intelligence to gain continuous and reliable visibility into recycling streams,” said Ambarish Mitra, Co-founder and CPO of Greyparrot. “This helps us improve recycling operations by placing waste intelligence into the hands of the people who are recovering, redesigning and remanufacturing the objects we throw away. We are thrilled to work with our U.S. partners towards our vision of a future where every piece of waste is valued as a resource.”

The collaborative project––a first of its kind in North America––will run for more than six months. During that period, it will gather data on the composition of PP bales over time, while accounting for seasonality. That insight can help determine the potential untapped value in these streams, and identify other materials that might be coming through unintentionally. This data can also help shed light on the presumed volume of food-grade material being captured in the system, along with opportunities for recovery and separation into distinct value chains. More broadly, this can advance a circular economy for valuable materials, improve material quality delivered to recycling facilities, and enhance the value of recyclable commodities shipped to U.S. end markets.

“A lot is unknown about the curbside polypropylene stream today. Filling these knowledge gaps can increase the pace of development for material recovery. Understanding the composition of the stream in a large-scale study highlights potential, reduces risk for pioneers and accelerates better design implementation. This study will be the catalyst to developing much larger-scale recycling of polypropylene,” said Curt Cozart, President of Common Sense Solutions and Technical Advisor to the project.

PP cup recovery––alongside material innovation, reuse and fiber cup recovery––is a critical focus for the NextGen Consortium. According to The Recycling Partnership, more than 2 billion pounds of PP are generated every year by single-family households in the U.S. If just 30% of this material were recovered, it would reduce greenhouse gas emissions by over 300,000 metric tons, providing over 600 million pounds of valuable raw material to companies with recycled content commitments for their foodservice packaging, both voluntary and mandated.

The NextGen Consortium has been actively involved in PP recovery since 2021, when it joined The Recycling Partnership’s Polypropylene Recycling Coalition as a Steering Committee member. Through this initiative, the group helps to fund equipment grants for MRFs so that they can effectively capture PP packaging, and improve community recycling access rates. In addition to improving recycling access, the NextGen Consortium is committed to driving recycling rates by supporting the recovery of post-consumer recycled content (PCR) that can be re-incorporated into packaging.

This collaboration with Greyparrot and MRFs across the U.S. is one critical step toward achieving the NextGen Consortium’s goals. As more data about the PP material stream is captured over the next six months, the Consortium will analyze the new data, identifying opportunities to improve PP sortation and recovery into higher value, new food-grade applications and areas where more research is needed. The NextGen Consortium continues to invite additional MRFs to participate in the project, to gain a better understanding into what is flowing through their material streams and identify ways to drive more value to the system.

About the NextGen Consortium

The NextGen Consortium is a multi-year consortium that addresses single-use food packaging waste globally by advancing the design, commercialization, and recovery of food packaging alternatives. The NextGen Consortium is managed by Closed Loop Partners’ Center for the Circular Economy. Starbucks and McDonald’s are the founding partners of the Consortium, with The Coca-Cola Company and PepsiCo as sector lead partners. JDE Peet’s, Wendy’s and Yum! Brands are supporting partners. The World Wildlife Fund (WWF) is the environmental advisory partner. Learn more at www.nextgenconsortium.com.

About the Center for the Circular Economy at Closed Loop Partners

Closed Loop Partners is  at the forefront of building the circular economy. The company is comprised of three key business segments: Closed Loop Capital Management, the Center for the Circular Economy and Circular Services. In 2018, Closed Loop Partners launched its innovation center, the Center for the Circular Economy, which unites competitors to tackle complex material challenges and to implement systemic change that advances the circular economy. Closed Loop Partners brings together designers, manufacturers, recovery systems operators, trade organizations, municipalities, policymakers and NGOs to create, invest in, and support scalable innovations that target big system problems. Learn more about the Center’s work here.

FALLS CHURCH, Va., March 31, 2021 — The Recycling Partnership today announced a second round of grant funding through its Polypropylene Recycling Coalition, distributing nearly $1 million in catalytic grants to advance polypropylene recycling in the U.S. Launched in July 2020, the Polypropylene Recycling Coalition (Coalition) is a cross-industry collaboration supported by steering committee members Keurig Dr Pepper, Braskem, NextGen Consortium, and the Walmart Foundation, along with other members of the polypropylene value chain. Polypropylene, sometimes referred to as No. 5 plastic, is used in an array of food and non-food packaging and is in strong demand as a recycled material.

Through its second round of grant funding, the Coalition will provide an additional three grants to Materials Recovery Facilities (MRFs) across the United States to boost sortation of polypropylene and support targeted consumer education efforts. To date, the Coalition has awarded grants for seven MRFs across the U.S. These investments aim to improve curbside polypropylene recycling access for an additional 3% of all U.S. households, impacting a total of 7.2 million people nationally. This aims to increase the recovery of polypropylene by an estimated 4,300 tons annually to be made into new products, such as consumer packaging and automotive parts, rather than being sent to landfills or incineration.

“The Polypropylene Recycling Coalition is leading the effort to rapidly drive meaningful, measurable change that will improve and increase the capture of polypropylene in U.S. curbside recycling. We continue to encourage all companies that use polypropylene to join us in being part of the solution to ensure greater and better capture of this recyclable material,” said Sarah Dearman, Vice President of Circular Ventures, The Recycling Partnership. “This fast, meaningful, and collaborative work will support jobs, preserve natural resources, and help support the transition to a circular economy in the United States.”

The Coalition awards grants to MRF candidates that face significant challenges in their ability to effectively sort and recycle polypropylene. With these strategic investments, polypropylene will now be accepted curbside in more communities and sent to established end markets, encouraging the shift to a circular economy. Further supporting the shift, community members in these areas will also be educated as to what is and isn’t accepted in their curbside recycling.

The three newest grantees include:

• American Recycling in Candler, North Carolina
• DEM-CON in Shakopee, Minnesota
• Independent Texas Recyclers in Houston, Texas

The combined geographic reach of the first two rounds of grantees includes MRFs across the Northern, Southern, Eastern, and Western regions of the U.S. The widespread interest and commitment from MRFs across the U.S. to growing the collection and sortation of recyclable polypropylene clearly demonstrates the market strength for this material nationwide.

The Coalition received a strong response to both the first and second rounds of requests for proposals and continues to accept grant applications to further its efforts to advance polypropylene curbside recycling. The next grant proposal request is due June 30, 2021. MRFs interested in sorting and recycling polypropylene are encouraged to apply.

The mission-driven work of the Coalition is supported by contributions from organizations representing all segments of the material’s value chain, including the Coalition’s newest member, Sabert Corporation. In addition to the aforementioned steering committee members, other members of the Coalition include American Chemistry Council, Campbell Soup Company, Danone North America, EFS-plastics, The Kroger Co. Zero Hunger | Zero Waste Foundation, KW Plastics, LyondellBasell, Merlin Plastics, Milliken & Company, Nestlé, PolyQuest, Procter & Gamble, St. Joseph Plastics, and Winpak. The Polypropylene Recycling Coalition is advised by industry leaders including: Association of Plastic Recyclers, former EPA Administrator Carol Browner, Closed Loop Partners, Sidewalk Infrastructure Partners, Sustainable Packaging Coalition, and World Wildlife Fund.

The Coalition is part of The Recycling Partnership’s Pathway to Circularity, an initiative creating scalable solutions to packaging and system challenges to accelerate the shift to a circular economy that uses fewer finite resources.

To learn more about the Polypropylene Recycling Coalition, its members, and how to get involved in supporting its goals, visit recyclingpartnership.org/polypropylene-coalition. For MRFs interested in applying for a grant, the application is available on our website.

About The Recycling Partnership
The Recycling Partnership is the action agent transforming the U.S. residential recycling system for good. Our team operates at every level of the recycling value chain and work on the ground with thousands of communities to transform underperforming recycling programs and tackle circular economy challenges. As the leading organization in the country that engages the full recycling supply chain, from working with companies to make their packaging more circular and help them meet climate and sustainability goals, to working with government to develop policy solutions to address the systemic needs of the U.S. recycling system, The Recycling Partnership positively impacts recycling at every step in the process. Since 2014, the nonprofit change agent diverted 230 million pounds of new recyclables from landfills, saved 465 million gallons of water, avoided more than 250,000 metric tons of greenhouse gases, and drove significant reductions in targeted contamination rates. Learn more at recyclingpartnership.org

About the NextGen Consortium

The NextGen Consortium is a multi-year, global consortium that addresses single-use food packaging waste globally by advancing the design, commercialization, and recovery of food packaging alternatives. The NextGen Consortium is managed by Closed Loop Partners’ Center for the Circular Economy. Starbucks and McDonald’s are the founding partners of the Consortium, The Coca-Cola Company, Yum! Brands, Nestlé, Wendy’s and Jacobs Douwe Egberts are supporting partners. World Wildlife Fund (WWF) is the advisory partner and IDEO is the innovation partner. Learn more at www.nextgenconsortium.com.

Media Contact:
Samantha Kappalman
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SOURCE The Recycling Partnership