Bio-based plastics are now seen as an eco-friendly substitute for traditional fossil-based plastics. Interestingly, aside from their environmentally friendly origins and in some cases, their biodegradability, bio-based plastics present a promising market potential for recycling, particularly through chemical depolymerisation. Nevertheless, before recycling, bio-based plastics must first be separated and isolated from other packaging materials. Achieving effective sorting of bio-based plastics presents a challenge in the market, as bio-based plastics require scale to be sorted and to form a circular economy. Yet, they also need circularity as a sustainability selling point to boost their sales. The PROSPER project brings together three bio-based plastic producers (including PLA and AAPE-blend producers), a major brand owner, an EPR scheme/PRO participant, a supplier of AI-sorting technology, a sorting testing center, four waste management companies, a municipality and a specialised consultant. It is supported by the scientific expertise of three research institutions and universities, as well as a policy-oriented non-profit organisation. The project offers a comprehensive approach by developing policy interventions, EPR fee scenarios and quantifying recycling rates and cost benefits associated with these scenarios. It also focuses on demonstrating technical advancements in sorting and recycling at industrial scale inside four real waste management companies. PROSPER will also evaluate the market potential for recycled bio-based plastic products through consumer studies, engagement with companies and PROs, while also assessing the Life Cycle, Social Life Cycle, material circularity indicators and economic business models. The institutionalisation of a system change by the different stakeholders in the bio-based plastics value chain will be crucial in achieving circularity, improving environmental performance and fostering positive impacts in the bio-based economy.

The AFTER-BIOCHEM project aims to create multiple new value chains, from non-food biomass feedstock to multiple end-products, by combining anaerobic batch fermentation and esterification. In the fermentation process robust mixes of naturally occurring micro-organisms will produce organic acids such as propionic, butyric, isobutyric, valeric, isovaleric and caproic acids, with a mineral fertilizer sidestream. Based on the acids, a substantial number of derivatives may be produced, such as Vinyl Acetate Monomer (VAM) and cellulose acetate. The esterification process will convert the acetic acid into ethyl acetate and the propionic acid into ethyl propionate to maximize product value and minimize waste and energy use. The feedstock of the fermentation process may be sugar production byproducts such as beet pulp and molasses, to increase the sustainability of sugar beet, a key European crop. The products will represent valuable renewable, bio-based, domestically-sourced alternatives to petrochemical products in numerous high-value applications such as flavorings and fragrances, hygiene products, pharmaceuticals, antimicrobials and polymers. The mineral fertilizer sidestream will contribute to the EU Action plan for the Circular Economy. The objective from 2020 to 2022 will be to commission the flagship biorefinery in France, which will then run at full capacity and integrate esterification from 2022 to 2024. Two further biorefineries should be initiated in Europe from 2024. The annual revenue generated by the three plants represents ca. €150 million, and at least 180 direct technical jobs and a commensurate number of indirect jobs would be created.

CIRCULAR FoodPack aims to facilitate the circular use of plastic packaging addressing the most sensitive product category: Food packaging. This sector contains 87% of all European flexible plastic-plastic multilayer composites (MLC) due to the high requirements for food preservation and safety. However, these MLC laminates cannot be recycled by state of the art processes and thus counteract the circular use of food packaging. Recycled polymers from far less demanding mono-film waste fractions underperform and cannot be used in food packaging, mostly due to the presence of intentionally and not intentionally added substances. We will demonstrate the project results by production of high-quality recycled PE at TRL 5-6, using Sensor-Based-Specification or Tracer-Based-Sorting (TBS, SBS), deinking and thermally assisted deodorization as well as solvent-based or mechanical recycling processes. Innovative designs of recyclable and food-safe mono-material laminates will enable the re-use in high-value film applications, with upcoming food packaging marking with deinkable tracers. This allows a future circular economy of food packaging, if TBS guarantees a sorting of food grade materials. Product characterization, food contact compliance testing, LCA, LCC and business modelling will support and guide process development, upscale and design new packaging. The approach addresses the scope of the call exactly, since innovative sorting and recycling solutions are applied to novel designs being developed. That enables the re-use in the same high-value product sector by removing undesirable substances from secondary raw materials. Addressing the annual 2 Mio tonnes of European MLC food packaging, which currently hamper the recycling of 17.8 Mio tonnes of food packaging waste, the expected impact on flexible packaging and food sector is substantial. An interdisciplinary team of 4 RTOs and 10 industrial partners (5 SMEs) will finally implement the new circular economy approach.