In the 1990s, the plastics industry introduced the idea that plastic products were recyclable. Yet, most experts predict that plastic waste will double again by 2040.
Only about 10% of the plastic we produce is recycled, compared to approximately 40% of paper (1). What does recycling actually mean? Why is recycling not what was envisioned 40 years ago? And what does it truly involve?
According to the U.S. Environmental Protection Agency, recycling is “the process of collecting and processing materials that would otherwise be thrown away and turning them into new products.”
In California, recycling refers to “the process of collecting, sorting, cleaning, processing, and reclaiming materials that would otherwise be disposed of on land, in water, or in the atmosphere,” and explicitly excludes combustion, incineration, energy generation, and fuel production.
The Packaging and Packaging Waste Regulation is equally clear: recycling means any recovery operation by which waste materials are reprocessed into products, materials, or substances—whether for their original purpose or other purposes—excluding biological treatment, energy recovery, or use as fuel or backfilling material.
However, Canada takes a different approach. Environment and Climate Change Canada defines recycling as a process that involves, at a minimum, collection, sorting, and recovery. Under this definition, incineration can be considered a form of recycling if it diverts waste from landfill. Nevertheless, available data show that, under current systems, packaging that could be recycled is often sent to landfill at various stages (2).
Québec’s 2024–2029 Strategy for the Reduction and Responsible Management of Plastics offers little additional clarity, despite the term being used extensively throughout the document.
Mechanical Recycling of Industrial Waste
The most basic form of recycling is mechanical recycling of industrial waste—also known as post-industrial waste—either within the same plant or between different facilities. Plastic waste generated during production is almost always reprocessed and reintroduced into manufacturing.
While this may seem straightforward, several challenges arise:
- Does the material change color?
- Are there printing inks on the surface?
- Does quality degrade?
- Are the materials compatible?
- Do they meet food-contact regulations?
- Do they contain incompatible or toxic additives?
Mechanical recycling is most effective when recycled materials are similar to virgin materials. Waste is shredded, melted, and formed into granules known as recyclate, which can then be reintroduced into production. It remains the most common recycling method.
However, when materials are contaminated, mixed, or contain inks or toxic additives, mechanical recycling leads to lower-quality outputs, limiting applications to low-value products such as park benches or garbage bags.
Advanced Recycling of Industrial Waste
Advanced recycling encompasses a wide range of methods that modify the chemical structure of plastics and remove impurities. It enables the transformation of post-industrial or post-consumer plastic waste into higher-value materials.
These systems can produce high-quality outputs such as liquid and gaseous chemicals, waxes, and lubricants for various applications. The best results are achieved when the plastic stream is well sorted and composed of a single polymer type.
Advanced recycling can be divided into six main categories:
1. Chemical purification by dissolution
Plastics are dissolved in organic solvents to remove impurities. The purified polymer is then recovered by precipitation, resulting in high-quality material—often slightly inferior to virgin plastic but superior to mechanically recycled plastic.
2. Chemical recycling by solvolysis
Polyesters such as PET are broken down into their original chemical components (e.g., MEG and DMT), which are then reused to produce new PET. This approach can reduce greenhouse gas emissions by 20–30% compared to petroleum-based production (5).
3. Enzymatic recycling
Specialized enzymes break down PET into its original monomers. This process is highly selective and operates at lower temperatures, though it remains costly due to enzyme requirements.
4. Thermochemical processes
Energy-intensive processes that break mixed plastics into basic chemical components, fuels, or synthetic gases. Reactor temperatures can reach up to 1,200°C.
5. Microwave-assisted pyrolysis
Microwave energy replaces conventional heat to break plastics into liquid chemical components, followed by purification to remove contaminants.
6. Catalytic cracking at low pressure
Plastics are partially broken down into waxes under controlled conditions. This process is often used to produce additives for asphalt and roofing materials.
Toward a Circular Plastic Economy
A combination of bio-based and compostable materials, advanced recycling technologies, and improved packaging design will be essential to achieving zero plastic waste within the next 20 years.
Advanced recycling is one of the most effective ways to divert plastics from the environment. However, it requires significant time and investment to scale. Improvements in collection and sorting systems, as well as the construction of new facilities, will be necessary to reduce costs and increase adoption.
Compostable plastics derived from non-petroleum sources, combined with biological and chemical processes, can also play a complementary role in sustainable waste management.
By Roger Tambay, special collaboration
Roger Tambay, B.Sc., M.B.A., B.C.L., LL.B., is a lawyer and Director of Sustainable Development at the Society of Plastics Engineers (SPE) – Québec Section.
[1] Seulement 38% des articles en carton et papier seraient recyclés aux États-Unis. Paper and cardboard waste in the United States: Geographic, market, and energy assessment. Milbrant (Amelia), Zuboy (Jarett), Coney (Kamyria) et Badgett (Alex), Waste Management Bulletin, bulletin 2 (2024) aux pages 21 à 28.
[3] Une lettre de non-objection est une autorisation de la part de la FDA permettant le contact alimentaire avec les articles d’emballages fabriqués à partir d’une matière recyclée.
[5] https://cen.acs.org/environment/recycling/Eastman-build-250-million-plastics/99/web/2021/02
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