BOBST’s oneBARRIER sustainable solutions, PrimeCycle and FibreCycle, have officially been declared recyclable. The certification of recyclability for PrimeCycle was obtained from Institute cyclos-HTO GmbH, with a rating of 98%. Similarly, FibreCycle, which is a barrier paper solution with BOBST AluBond, received a recyclability assessment of 94.4% from the German paper research institute PTS.
Nick Copeland, the R&D Director of Barrier Coatings at BOBST, played a significant role in the development of the oneBARRIER solutions. In an interview with him, he discussed the implications of the certification for BOBST and its customers.
The original target for PrimeCycle was to replace mixed polymer multi-layer flexible packaging structures with a mono-material PE-based solution. The goal was to maximize the amount of PE in the structure, achieving high barrier performance with a simplified 2-layer duplex structure. The performance targets for the AlOx transparent solution were to replace Metallized PET with OTR <1 cc/m2/day and WVTR <1 gm/m2/day. For the AluBond opaque solution, the aim was to replace Aluminum Foil with OTR and WVTR below 0.1. These targets were based on the prevalent high and ultra-high barrier solutions in the flexible packaging industry.
According to Copeland, the targets were successfully achieved in terms of performance and mono-material percentage. The solutions met the barrier and adhesion market targets, while maintaining a high percentage of PE as per the European CEFLEX guidelines.
The certification of PrimeCycle signifies not only its recyclability but also provides an independent assessment of the recycling percentage. This allows the industry to compare different mono-material solutions and identify regions where the necessary collection and mechanical recycling infrastructure is in place.
Copeland mentioned that the recyclability assessments were crucial in determining the suitability of the solutions for mechanical recycling. He highlighted the importance of understanding the different recycling assessments and protocols in each market to ensure compliance with the local infrastructure.
Regarding FibreCycle, the goal was to replace mixed polymer multi-layer packaging structures with a mono-web structure using paper or fiber. The target barrier performance for FibreCycle aimed to replace Metallized PET with OTR <1 cc/m2/day and WVTR <1 gm/m2/day, with an aspiration of Al foil replacement with OTR and WVTR below 0.1. Copeland confirmed that the barrier performance targets were met, and the solution is one of the best performing in the market.
The accreditation for FibreCycle provides an independent assessment of its recyclability, including yield percentage, optical impact, and potential issues related to non-fiber content. This allows for a detailed comparison of different fiber-based solutions, especially considering the challenges in achieving high or ultra-high barrier performance while maintaining a high fiber percentage.
Copeland emphasized the significance of successful independent recycling assessments in gaining confidence from interested parties. The mature collection, sorting, and recycling infrastructure for paper-based packaging make FibreCycle attractive in markets beyond Europe, such as North America, Asia, and Africa.
Collaboration with various partners was essential for the development of both PrimeCycle and FibreCycle. Copeland highlighted the ambitious sustainability pledges and commitments throughout the value chain, which necessitate collaboration to meet the demanding timelines. The challenge lies in providing comparable performance with sustainable materials that often have inferior properties compared to traditional non-recyclable options. Cross-industry collaboration with experts becomes crucial in fast-tracking complex sustainability projects like the oneBARRIER solutions.
BOBST’s oneBARRIER solutions have demonstrated their recyclability and performance, paving the way for a more sustainable future in the packaging industry.