Collecting packaging and remanufacturing it into new products might sound simple. And it’s not especially difficult when everyone involved has the common goal of finding more environmentally sustainable solutions. But breaking down the process into its individual phases allows us to better understand what’s essential for future developments.
The closed-loop recycling pilot project began in 2020. However, the coronavirus pandemic soon disrupted things, slowing down collection.
“Some of our collection sites were not operational during the pandemic,” says Heidi Kähkönen, packaging development manager for Kiilto’s professional hygiene and consumer business units.
Once the external difficulties were overcome, the collection phase was successfully completed in autumn 2022. Customers could choose from three collection methods to suit their needs.
“Some customers collected empty packaging in 660-litre waste bins lined with plastic sacks. The second option was a metal cage for IBC containers (intermediate bulk containers), lined with a large plastic sack, and the third collection container was a reusable cardboard box. Customers were instructed to rinse the packaging before placing it in the collection container. Caps were not collected.”
LHJ Group managed the transport of the collected packaging. The cities of Kotka and Hamina joined the collection pilot in June 2021.
“The logistics work fine. Processing the packaging requires very little extra effort from the staff. A light rinse of the bottles and canisters before collection is enough,” cleaning services manager Leena Järvinen of the City of Kotka said at the time.
Efficient transport
During the collection period, Kiilto customers gathered a total of 5,500 kilograms of empty packaging – exactly the pilot’s target amount. Pasi Kaskinen from LHJ Group has some ideas on how logistics could be improved.
Finland is geographically dispersed, so to increase efficiency, we should develop ways to crush or bale packaging along the transport route. Transport efficiency could also be improved by focusing collection efforts where the most packaging waste is generated. It would also be important to consider how to integrate empty packaging transport into existing logistics systems,” Kaskinen says.
“It was great to be part of this project. I hope the pilot will continue. It would be fantastic if the closed-loop recycling model became a permanent solution.”
Different plastic types should be collected
After collection, the packaging was sent to Lassila & Tikanoja (L&T) for recycling and processing.
Mikko Mäenpää of L&T was impressed by how well all the parties worked together.
“Some things should be left simple.
Any type of plastic that can be separately collected should be sorted. If there’s a particular plastic fraction that is generated in large quantities, it’s definitely a good idea to think about whether it could be further processed – if not into the same product, then something new.” Sorting at the source is essential for maintaining quality, Mäenpää emphasises, highlighting the commitment required from collection sites to ensure proper recycling.
Kaskinen agrees.
“Sorting technologies are continuously improving, making it easier to collect cleaner plastic. The purer and more homogeneous the plastic is when it’s recovered, the broader the range of possible applications.”
Recycled plastic content nearing its maximum feasible limit
Once the collected packaging was processed into granulate, the next step was to test its use in new packaging production. The packaging was manufactured by Muovi-Heljanko, which received five sacks of granulate for the trial.
“We tested the material batch by batch. The process was adjusted according to the plastic quality, as the melt flow indices varied,” says the company’s managing director, Simo Heljanko.
The melt flow index (MFI) is a measure of how polymer melts flow under standard conditions. This is crucial for packaging success, as thermoplastics are melted to produce different products.
“Because the melt flow index varied, it affected the weight and pressure distribution of the canisters,” Heljanko explains.
The new canisters are multi-layered, with virgin plastic forming the inner and outer layers, while the middle layer contains recycled plastic. According to Heljanko, the 35% recycled plastic content in the new packaging is approaching the current feasible maximum. The packaging must pass all necessary tests to receive regulatory approval.
“The use of recycled plastic in packaging production is increasing across the board. We’ve worked with recycled plastic for years, but this was our first collaborative closed-loop recycling test.”
“We have invested in production, and much of it is now automated. The production lines for these canisters are in place, and we have the capacity to produce more. However, the cost of closed-loop recycling is slightly higher than that of packaging made entirely from virgin raw materials. Elsewhere in Europe, closed-loop recycling is likely already in use due to larger production volumes,” Heljanko points out.
For high-quality production, it is essential to know the source of the recycled plastic and its contents.
Plastic types must be clearly labelled. This pilot provided us with a very positive experience. Similar initiatives are entirely feasible in the future.”
Should closed-loop packaging be a sustainability requirement?
According to Kähkönen, discussions about the possibilities of closed-loop recycling have continued even after the pilot project ended. There is genuine interest in developing a closed-loop packaging ecosystem in Finland.
“Creating an ecosystem like this requires collaboration and funding, and of course an understanding of what’s needed for success. Now that we have successfully trialled closed-loop recycling for Kiilto’s professional hygiene packaging, we are happy to share our knowledge and insights more widely. Personally, I hope that closed-loop recycling of packaging materials will one day be considered a sustainability requirement.”
The packaging produced during the project will be used in selected Kiilto products starting in early 2025.
Further information:
Heidi Kähkönen
Packaging Development Manager
Heidi.kahkonen@kiilto.com
+358 40 837 0830