How to make smarter decisions about sustainable plastic production

Plastics are everywhere and they are here to stay. Due to their unique characteristics, lightweight nature and versatility, they contribute significantly to sustainability. From long-lasting construction materials to single-use packaging, plastics play a crucial role in many societal functions. However, there is a dark side to our current production and use of plastics.

The global plastics system is predominantly linear and based on fossil feedstocks, with only around 14% of plastic waste collected for recycling globally. Greenhouse gas emissions from fossil plastics production and use are substantial, accounting for almost 5% of global emissions. Additionally, plastics are notorious for their end-of-life impact, polluting the environment and breaking down into microplastics that harm both people and the planet.

To address these issues, society must find ways to produce, use and dispose of plastics more sustainably. Applying circular economy principles (the so-called “R-strategies”) to increase the refuse, reuse and recycling of plastics is essential. However, while we can refuse and reuse some plastic products, we cannot eliminate all plastics due to their unique functions that we rely on daily. To achieve the Sustainable Development Goals, the plastics industry must transition from fossil feedstocks to renewable carbon sources, such as recycled plastics, biomass, CO2 and green hydrogen.

Recycling will likely play a significant role in our future plastics system, as it effectively utilizes plastic waste feedstock and conserves resources. However, even if global recycling rates reach their theoretical maximum, only approximately 60-70% of total volumes can be produced from recycled plastic feedstock due to losses during production, usage, collection, (bio)degradation, microplastic formation and yield losses in the recycling process.

Therefore, in a fossil-free circular sustainable future, we need sustainable virgin plastics production to complement recycling. The remaining renewable carbon options are biomass and CO2. On top of that, projections indicate a sharp increase in global plastics demand towards 2050 driven by rising global living standards and industrialization. This means we must refuse, reuse and recycle as much plastic as possible, while also covering system losses and meeting growing demand with sustainable virgin production.

In a non-fossil sustainable plastics system, what share of plastics will be biobased? And what about captured CO2? Determining the best mix of renewable carbon for sustainable plastic production is challenging. The discussion around biobased plastics often remains high-level, focusing on whether bioplastics are always more sustainable in any application. The lack of a long-term perspective on renewable carbon pathways leaves policy-makers and industry unable to make effective decisions.

TNO, an independent research organization based in the Netherlands, suggests that to understand the role of biobased plastics, we need to examine different renewable carbon-basd pathways in view of product application. This involves matching the right feedstocks and conversion technologies with the right products and applications in the right geographical locations.

To this end, TNO developed a three-step framework to compare pathways to bio- and CO2-based plastics in view of application. The pathways for sustainable virgin production of plastics are defined as:

The three pathways need to be compared to determine the optimal balance of sustainability and economic feasibility for a specific product. The three steps of the framework: Search, Compare and Decide, are summarized in Figure 3 (below).

This approach lays the foundation for strategic choices regarding the best pathway to renewable carbon-based plastic per product, balancing sustainability and economic feasibility. It can estimate the performance of pathways or technologies at an early stage based on initial data.

The three steps are intentionally easy to follow. Although the approach seems simple, the underlying determination of sustainability and economic feasibility and subsequent system optimization requires thorough analysis of sustainability in a value chain approach, with system optimization on different impacts and constraints.

The framework can support global organizations, policy-makers and industry players such as brand owners, producers and compounders to quickly screen for the most sustainable and economically feasible solution for their product or scope. Aggregating results across all major plastics products allows stakeholders to develop insights into transitioning towards a circular sustainable future.

The quick identification of the most suitable pathway per plastic type and application provides guidance for the decisions and actions needed to achieve the transition. The compiled results also allow users to draw conclusions on the overall share of biobased versus CO2-based plastics and in which products bioplastic application makes the most sense, thereby unlocking market opportunities.

The three-step framework paves the way for solutions that are not just sustainable but also financially viable and beneficial for your competitiveness. Find out how you can apply the framework for your transition to sustainable plastics.