POST CONSUMER RESIN PACKAGING

Abstract

The present invention relates to a sustainable article for packaging which could be made substantially free of virgin petroleum-based compounds; in particular it relates to new packaging made from coloured post-consumer resin (PCR) having a high NIR absorption. A need remains to create a circular economy for coloured and/or black plastic by bringing the waste coloured and black plastic into new packaging while using Near infrared (NIR) detectable pigment in the colourant masterbatch. It is therefore an object of the present invention to bring the coloured or black plastic waste into new packaging. It has be found that a sustainable packaging in consumer acceptable black using NIR detectable pigment can be obtained by using a multilayer post-consumer resin, comprising a thinner outer layer of post-consumer resin of natural plastic waste (N-PCR); and a thicker inner layer comprising at least 50% coloured plastic waste (J-PCR).

Claims

1. A sustainable article for packaging comprising a multilayer post-consumer resin (PCR) wherein the multilayer comprises: an outer layer comprising post-consumer resin of natural plastic waste (N-PCR); and an inner layer comprising post-consumer resin of natural plastic waste (N-PCR) or coloured plastic waste (J-PCR) wherein at least 50% of the inner layer comprises post-consumer resin of coloured plastic waste (J-PCR), wherein the outer and/or inner layer comprises a NIR detectable colourant masterbatch and wherein the article is substantially free of virgin plastic which means that the article comprises less than 5 wt % of virgin plastic.

2. The article according to claim 1 wherein the inner layer comprises 100% of coloured plastic waste (J-PCR).

3. The article according to claim 1 wherein the weight ratio of the outer layer to the inner layer is 99:1 to 1:99, preferably 1:3 to 1:5, more preferably 1:4.

4. The article according to claim 1 wherein the multilayer comprises a second inner layer.

5. The article according to claim 1 wherein the NIR detectable colourant masterbatch is black.

6. The article according to claim 1 wherein the plastic waste is waste high-density polyethylene (HDPE).

7. The article according to claim 1 wherein the article comprises less than 3%, more preferably 0% of virgin plastic.

8. The article according to claim 1 wherein the article is a container.

9. The article according to claim 1 wherein the article is a non-food grade article.

10. The article according to claim 1 wherein the article comprises packaging for fast moving consumer goods (FMCG).

11. A sustainable non-food grade article for packaging, comprising: a multilayer post-consumer resin (PCR) wherein the multilayer comprises: an outer layer comprising post-consumer resin of natural plastic waste (N-PCR); and an inner layer comprising post-consumer resin of natural plastic waste (N-PCR) or coloured plastic waste (J-PCR) wherein at least 50% of the inner layer comprises post-consumer resin of coloured plastic waste (J-PCR), wherein the outer and/or inner layer comprises a NIR detectable colourant masterbatch; and wherein the article comprises less than 5%, preferably less than 3%, more preferably 0% of virgin plastic.

12. The article according to claim 11 wherein the inner layer comprises 100% of coloured plastic waste (J-PCR).

13. The article according to claim 11 wherein the weight ratio of the outer layer to inner layer is 99:1 to 1:99, preferably 1:3 to 1:5, more preferably 1:4.

14. The article according to claim 11 wherein the multilayer comprises a second inner layer.

15. The article according to claim 11 wherein the NIR detectable colourant masterbatch is black.

16. The article according to claim 11 wherein the plastic waste is waste high-density polyethylene (HDPE).

17. The article according to claim 11 wherein the article comprises packaging for fast moving consumer goods (FMCG).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0023] In a first aspect, the present invention relates to a sustainable article for packaging. The sustainable article of the present invention is made from post-consumer resin (PCR) and preferably is substantially free of virgin plastic.

[0024] By “substantially free” it is meant that the article comprises less than 5 wt %, preferably less than 3 wt %, more preferably less than 2 wt %, even more preferably less than 1 wt % or even 0 wt % of virgin plastic.

[0025] The PCR used in the present invention is recycled polyethylene, preferably recycled high-density polyethylene (HDPE).

[0026] Preferably, the article of the present invention comprises a multilayer post-consumer resin (PCR).

[0027] The multilayer comprises at least two layers: an outer layer and an inner layer.

[0028] The outer layer is typically the layer that is on the outside of the article, usually, directly visible to the consumer.

[0029] The outer layer of the multilayer comprises post-consumer resin of natural plastic waste (N-PCR). Natural plastic waste typically comes from waste milk or diary bottles or the similar.

[0030] The inner layer of the multilayer comprises post-consumer resin of natural plastic waste (N-PCR) or coloured plastic waste (J-PCR). Preferably, at least 50% of the inner layer comprises post-consumer resin of coloured plastic waste (J-PCR). Preferably, the inner layer comprises at least 60%, more preferably at least 70%, even more preferably at least 80%, still more preferably at least 90% or even 100% of coloured plastic waste (J-PCR).

[0031] Coloured plastic waste typically comes from waste coloured and/or mixed consumer bottles. Post-consumer resin of coloured plastic waste is commonly referred to as Jazz PCR (J-PCR).

[0032] Both N-PCR and J-PCR are available in the market from various suppliers such as Viridor, QCP and Biffa in Europe and KW plastics in North America.

[0033] When present as a bilayer, the weight ratio of the outer layer to inner layer is typically from 99:1 to 1:99, but preferably from 1:1, more preferably from 3:7 or even from 1:3, while preferably to 1:20, more preferably to 1:10 or even to 1:5

[0034] The multilayer of the present invention may further comprise a second inner layer, which when present will become the innermost layer which typically will be the layer in contact with the product.

[0035] When present, the second inner layer comprises post-consumer resin of natural plastic waste (N-PCR).

[0036] While the use of the outer layer of N-PCR is predominantly intended to provide a more intense colour on the outside of the article, the provision of the second inner layer (or innermost layer) of N-PCR in multi-layer articles reduces the malodour that often comes from J-PCR.

[0037] When present as a trilayer, the weight ratio of the outer layer to inner layer to second inner layer is from 1:1.5:1 to 1:98:1, but preferably from 1:2:1, more preferably from 1:3:1 while preferably to 1:18:1, more preferably to 1:10:1 or even to 1:8:1 or even to 1:5:1

[0038] Preferably the outer and/or inner layer comprises a colourant masterbatch. More preferably, the outer layer comprises a colourant masterbatch. By “colourant masterbatch” it is a meant a mixture in which pigments are dispersed at high concentration in a carrier material. The colorant masterbatch is used to impart colour to the article.

[0039] The carrier may be a biobased plastic or a petroleum-based plastic, or a biobased oil or a petroleum-based oil or made of post-consumer resin (PCR).

[0040] Nonlimiting examples of the carrier include bio-derived or oil derived polyethylene (e.g, LLDPE, LDPE, HDPE), bio-derived oil (e.g., olive oil, rapeseed oil, peanut oil), petroleum-derived oil, recycled oil, bio-derived or petroleum derived polyethylene terephthalate, polypropylene, recycled high density polyethylene (rHDPE), recycled low density polyethylene (rLDPE). Preferably the carrier is recycled high density polyethylene (rHDPE) or recycled low density polyethylene (rLDPE).

[0041] When it is desired that all the layers are made of 100% of PCR, the carrier is also preferably selected from PCR. Similarly, when it is desired that a layer has a 100% of a specific PCR, the carrier is preferably selected from the same PCR.

[0042] The pigment, when present, of the masterbatch is a NIR detectable pigment. Carbon black is not preferred in the scope of the present invention. The NIR detectable pigment is preferably black. The pigment is typically made of a combination of known colours.

[0043] By consumer acceptable black, it may be defined as the colour measured using a reflectometer and expressed as the CIE L*a*b* values and the values of L being less than 25, preferably less than 23, more preferably less than 20, even more preferably less than 15, still more preferably less than 12 or even less than 10, the values of a being in the ranges of −5 to 5, preferably −2 to 3, more preferably 0 to 2 and the values of b being in the ranges of −10 and 10, preferably −8 to 5.

[0044] By NIR detectable pigment is meant detectable by Near infrared (NIR) spectroscopy.

[0045] The pigment of the carrier may include, for example, an inorganic pigment, an organic pigment, a polymeric resin, or a mixture thereof.

[0046] Optionally, the colourant masterbatch can further include one or more additives. Nonlimiting examples of additives include slip agents, UV absorbers, nucleating agents, UV stabilizers, heat stabilizers, clarifying agents, fillers, brighteners, process aids, perfumes, flavors, and a mixture thereof.

[0047] Such NIR detectable pigments are known in the art and are provided by various suppliers such as Clariant, globally and Colourtone Masterbatch Ltd. in Europe.

[0048] The article according to the invention is preferably a container; in particular the article according to the invention is a non-food grade container.

[0049] Method

[0050] The article of the invention can be produced using blow molding. Blow molding is a manufacturing process by which hollow plastic parts are formed from thermoplastic materials. The blow molding process begins with melting down thermoplastic and forming it into a parison or preform. The parison is a tube-like piece of plastic with a hole in one end through which compressed air can pass. Pressurized gas, usually air, is used to expand the parison or the hot preform and press it against a mold cavity. The pressure is held until the plastic cools. After the plastic has cooled and hardened the mold opens up and the part is ejected.

[0051] There are three main types of blow molding: extrusion blow molding, injection blow molding, and injection stretch blow molding. In extrusion blow molding, a molten tube of plastic is extruded into a mold cavity and inflated with compressed air. One end of the cylinder is pinched closed. After the plastic part has cooled, it is removed from the mold. Extrusion blow molding can be used to produce the multilayer articles of the invention.

[0052] Use

[0053] In a further aspect the invention provides the use of the article according to the invention for packaging fast moving consumer goods (FMCG), such as personal care products, beauty products, cosmetic products, home care products and/or food products.

EXAMPLES

Example 1

[0054] In this Example, a bottle having both inner and outer layer made of J-PCR (Comp A) and coloured with 1% of the 80% layer with Colourtone F95884 and 4% of the outer layer with Colourtone F95884 is compared with a bottle having layers according to the invention and coloured with 1% of the 80% layer with Colourtone F95884 and 4% of the outer layer with Colourtone F95884 (Ex 1).

TABLE-US-00001 Weight ratio of outer to Outer layer Inner layer inner layer material Wt % material Wt % Comp A 20:80 J-PCR 20 J-PCR 80 Ex 1 20:80 N-PCR 20 J-PCR + 40 + 40 N-PCR Control 20:80 Virgin HDPE 20 Virgin HDPE 80

TABLE-US-00002 Pantone colour code L value a value b value Comp A Pantone 432c 25.68 −2.8 −7.33 Ex 1 Pantone 532c 11.95 1.26 −7.71 Control Pantone 2c 19.37 0.31 9.78

[0055] The resultant colour of the bottle of Comp A was greyer in colour even though it was coloured with a black coloured masterbatch (Colourtone F95884). The consumer acceptable black that is desired is obtained in the control bottle which uses virgin HDPE for both layers. This colour is matched by the colour of the bottle having layers according to the invention (Ex 1) but not Comp A.

Example 2

[0056] In this Example, trilayer bottle having all layers made of J-PCR (Comp B) and coloured with 3% of the 60% middle layer (inner layer) with Clariant PE94000797 and 3% of the 20% outer layer with Clariant PE94000804 are compared to bottles having layers according to the invention and coloured with 3% of the 60% middle layer (inner layer) with Clariant PE94000797 and 3% of the 20% outer layer with Clariant PE94000804 (E×2 and E×3).

TABLE-US-00003 Weight ratio of outer to Outer Inner Second inner layer Wt layer Wt inner Wt layer material % material % layer % Comp 20:60:20 J-PCR 20 J-PCR 60 J-PCR 20 B Ex 2 20:60:20 N-PCR 20 J- PCR 60 N-PCR 20 Ex 3 20:60:20 N-PCR 20 J- PCR + 30 + 30 N-PCR 20 N- PCR

[0057] The resultant colour of the bottle of Comp B was greyer in colour even though it was coloured with a black coloured masterbatch (middle layer (inner layer) Clariant PE94000797 and outer layer Clariant PE94000804). The consumer acceptable black that is desired was obtained in the bottles of Ex 2 and Ex 3 having layers according to the invention but not Comp B.