Environmental Impact Of OCTAL's DPET Sheet Is Superior To RPET In Consumer Packaging
Plano, TX - OCTAL Petrochemicals' proprietary DPET™ sheet has emerged as a replacement for recycled PET (RPET) sheet for clear thermoformed packaging for food, dairy, and consumer product markets. Retailers have a new option to achieve their sustainability goals while also realizing major quality and performance improvements.
Packaging companies throughout the world are increasingly moving to DPET sheet because of the combination of sustainability and product performance which was previously unavailable in the market. "Retailers are opting for DPET sheet because of the broad value it brings," said Paul Baldwin, OCTAL's European regional sales manager. "They can meet their sustainability goals but also produce a better performing package due to DPET's higher consistency, easy forming, and increased machine output." Retailers also gain improved aesthetics while downgauging, resulting in less packaging entering the recycling waste stream.
"DPET offers a viable solution to replace less environmentally accepted materials such as PVC/PE for form, fill, and seal applications where issues with cutting, blade wear, and inconsistency have presented obstacles to RPET," said Ian Bone, Managing Director of Südpack UK and Director of The Packaging and Films Association (PAFA). "With the increasing targets to reduce packaging entering the waste stream and a focus on reducing carbon footprint, DPET's arrival is timed perfectly to meet the needs of the industry."
The carbon footprint of DPET™ sheet is roughly the same as RPET blends with up to 50% recycle content, according to a recent independent study conducted by PIRA International, a leading UK consultancy and specialist in carbon footprint analysis. In addition, DPET™ sheet has unique downgauging capabilities which reduce packaging, and the waste generated from the sheet actually improves the quality of the PET recycling stream because it has the same properties as virgin resin (its properties have not been degraded by going through traditional extrusion methods).
The DPET™ sheet process is a more sustainable option because it is more efficient than standard polymerization and extrusion, uses less raw material (chemical precursors), and produces less non-recoverable waste, according to the study. The biggest energy savings is derived from the integration of the two-reactor polymerization system and the sheet forming process, the PIRA study notes.
For retailers, DPET™ sheet delivers a wide range of performance advantages over RPET. OCTAL has developed proprietary technology that integrates the PET reactor and melt pump to the die and calendering rolls. This direct PET (DPET™) process bypasses the compacting, drying, and melting processes of traditional systems, thus eliminating the cost and heat history. This results in the production of high-quality PET sheet with distinct advantages in terms of color, clarity, and purity. DPET™ has superior clarity than RPET and has no color tint - unlike RPET which typically has color variation due to the post-consumer waste (PCW) component.
DPET™ sheet provides greater product consistency and higher productivity than RPET. Batch after batch gives identical performance allowing thermoforming lines to be optimized for maximum output. RPET's inherent variability results in inconsistency, a slower production process, and additional waste. DPET™ sheet boasts a higher modulus than RPET (280,000 psi vs. 180,000 psi). Due to this greater stiffness, downgauging by up to 12% over RPET is achievable without affecting package performance.
During thermoforming, DPET™ sheet requires less heat than RPET, resulting in faster cycle times and more parts per minute. The material also offers a higher intrinsic viscosity (I.V. of 0.78) than RPET, resulting in more consistent flow and less brittleness along with haze less than 2%. A thickness tolerance of ±1% compared to ±5% for standard RPET sheet permits tighter yield control. When gauge is held to less than 1% variation, packaging manufacturers can better determine the number of parts they can produce per ton of DPET™ sheet, says Baldwin. Improved gauge control means major productivity advantages for thermoformers who can improve throughput, reduce waste, and cut costs from 3% to 8% with the DPET™ process.
DPET™ sheet is easier to cut than RPET, particularly in form, fill, and seal applications. Frequent problems associated with cutting RPET such as ragged edges, incomplete cuts, and excessive blade wear are greatly reduced.
Industry observers question the future sustainability of RPET sheet due to the limited supply of PCW which is increasingly being used in other applications such as blow molded bottles.
SOURCE: OCTAL Petrochemicals LLC