In August 2023, Toppan, Mitsui Chemicals Tohcello, and Mitsui Chemicals commenced pilot testing for the horizontal recycling of printed BOPP film, transforming it into new flexible packaging film. This collaborative effort is aimed at developing cutting-edge technologies and operational systems for recycling flexible packaging materials on a horizontal scale. Additionally, the companies intend to capitalize on the growth of the flexible packaging industry’s network to promote and extend the horizontal recycling of flexible packaging film.
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 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 material converters, remove any ink from it, turn the remaining material into pellets and turn those pellets into new flexible packaging film. Then in December 2022, Toppan, Mitsui Chemicals Tohcello and Mitsui Chemicals initiated discussions to lay the groundwork for the joint pilot testing commenced on 2 August 2023.
Fiscal 2023 marks the beginning of full-fledged joint pilot testing, with BOPP film waste – generated by Toppan from processes such as printing adjustment – being recovered by Mitsui Chemicals, which also removes the film waste’s printing and converts it into pellets that are in turn made into recycled BOPP film by Mitsui Chemicals Tohcello. Toppan is also evaluating the recycled BOPP film’s quality, with a particular eye toward its suitability for the likes of printing, lamination, and the creation and filling of flexible pouches. The lamination process here makes use of eco-friendly adhesive from Mitsui Chemicals.
Through this initiative, the three companies aim to have this technology implemented in society by fiscal 2025 in line with the milestone laid out by the Ministry of the Environment’s Resource Circulation Strategy for Plastics.
Role of each company
Mitsui Chemicals is recovering used film, removing printing from that film, turning it into recycled pellets and providing quality control. Mitsui has Polypropylene resin expertise (for resin composition, modification, measurement and analysis technology, etc.)
Mitsui Chemicals Tohcello is producing recycled film and providing quality control. The company has expertise in BOPP film production technology.
Toppan is supplying used BOPP, converting the recycled film, and running sales and marketing. It has expertise in converting technology (including recycled film expertise), as well as the ability to roll out downstream offerings