A partnership of three companies has been working since August 2023 on a joint pilot test for the horizontal recycling of printed BOPP flexible packaging film. And now, the three companies – Toppan Holdings, RM Tohcello and Mitsui Chemicals– have developed a recycled BOPP film suitable for mass production. The companies will begin providing samples of this film within October 2024.
The creation of this film sees printed film waste generated by Toppan get collected and taken to Mitsui Chemicals’ Nagoya Works, where the ink is removed and the waste is turned into pellets. These pellets are then turned into film by RM Tohcello. The recycled film has been tested for mass production purposes at Toppan packaging facilities, with the results finding it to be suited for mass production processes such as printing, laminating, and pouch forming. The companies have also evaluated the physical properties of the film in pouch form, confirming that it is fit for use as packaging.
The samples to be provided will be displayed at Toppan’s stand (2U09, East Hall 2) and Mitsui Chemicals’ stand (1R07, East Hall 1) at Tokyo Pack 2024, an event set to be held at Tokyo Big Sight over 23–25 October 2024.
Background
The Japanese government’s Resource Circulation Strategy for Plastics includes a target of transitioning to reusable or recyclable plastic designs by 2025. Milestones under the strategy for 2030 include that 60% of plastic containers and packaging should be reused or recycled, and that the recycling of plastic resources should be doubled. With 2025 as an important starting point toward those milestones, it will be essential for companies engaged in the industry to expand efforts for reuse and recycling on the way to 2030.
In May 2022, Mitsui Chemicals launched RePLAYER Renewable Plastics Layer System, an initiative that aims to recover film waste from flexible packaging converters, remove any ink from it, pelletize the remaining material and turn those pellets into new flexible packaging film. Then in December 2022, Toppan, RM Tohcello and Mitsui Chemicals began discussing the basis of a joint pilot testing project. Fiscal 2023 marked the beginning of full-fledged joint pilot testing – and now, with the companies having confirmed mass production suitability with regard to printing, laminating and pouch forming, as well as physical properties including seal strength and tear resistance when in pouch form, the companies are ready to start providing sample pouches.
Goals
With this pilot testing project, Toppan, RM Tohcello and Mitsui Chemicals have established a technological and operational framework for the horizontal recycling of flexible packaging film. The companies hope to see their new material enter into society within fiscal 2025 with an eye toward further developing and popularizing the horizontal recycling of flexible packaging film.
Mitsui Chemicals Group, which has knowledge about polypropylene resins (e.g. resin composition; modification; measuring & analysis technology), collect film waste generated by Toppan, remove printing, repelletize and carry out quality control.
RM Tohcello with its BOPP film manufacturing technology produce and carry out quality control on recycled film. Toppan will supply BOPP film waste, convert recycled film, and carry out sales and marketing.
Smarts is a sustainable brand under the Toppan Group that begins with packaging. By combining the technologies and expertise the group has cultivated in the packaging realm with resources such as marketing, digital transformation and business process outsourcing, the brand looks to offer optimal choices tailored to the entire value chain. Toppan intends to work with its stakeholders to help build a sustainable society using the wide-ranging solutions under the Smarts banner.
Seeing climate change and the problems posed by plastic as part of the same challenge, Mitsui Chemicals aims to achieve carbon neutrality and create a circular economy to ensure that it can continue contributing to society as a chemical company. The company is enhancing its range of biomass-based products and developing recycling technologies and systems with this goal in mind.
Under RePLAYER, Mitsui Chemicals will rethink the way it handles plastic waste and other waste products and reuse them as resources. By developing new materials, recycling systems and value chains, Mitsui Chemicals will create a robust circular economy loop that encompasses a broader part of society.
