A collaborative effort involving three companies—TOPPAN Inc., RM Tohcello Co., Ltd., and Mitsui Chemicals, Inc.—has been in progress since August 2023, aimed at conducting a pilot test for the horizontal recycling of printed BOPP (biaxially oriented polypropylene) flexible packaging film.

After months of dedicated research and development, the partnership has achieved a significant milestone by creating a recycled BOPP film that is suitable for mass production. This advancement represents a crucial step toward enhancing sustainability in the packaging industry, as it addresses the challenges associated with recycling flexible packaging materials.

Starting in October 2024, the three companies will begin providing samples of this newly developed recycled BOPP film. This initiative not only highlights their commitment to innovation and environmental responsibility but also positions them to meet the growing demand for sustainable packaging solutions in the market. The collaboration aims to demonstrate the viability of using recycled materials in flexible packaging, paving the way for more eco-friendly practices within the industry.

The development of this recycled BOPP film begins with the collection of printed film waste generated by TOPPAN. This waste is transported to Mitsui Chemicals’ Nagoya Works, where the ink is removed, and the material is processed into pellets. These pellets are subsequently transformed into film by RM Tohcello.

Extensive testing has been conducted at TOPPAN's packaging facilities to assess the recycled film's suitability for mass production. The results indicate that the film is compatible with various production processes, including printing, laminating, and pouch forming. Additionally, the companies have evaluated the physical properties of the film in its pouch form, confirming its viability as packaging material.

Samples of this innovative recycled film will be showcased at TOKPAN’s booth (Booth Number 2U09, East Hall 2) and Mitsui Chemicals’ booth (Booth Number 1R07, East Hall 1) during TOKYO PACK 2024. This event is scheduled to take place at Tokyo Big Sight from October 23 to 25, 2024, providing an excellent platform for the companies to present their advancements in sustainable packaging solutions.

The Japanese Government's Resource Circulation Strategy for Plastics outlines an ambitious goal of transitioning to reusable or recyclable plastic designs by 2025. As part of this strategy, key milestones for 2030 include achieving a 60% reuse or recycling rate for plastic containers and packaging and doubling the recycling of plastic resources. With 2025 serving as a critical starting point for these objectives, it is vital for companies in the industry to intensify their efforts toward reuse and recycling to make significant progress by 2030.

In May 2022, Mitsui Chemicals launched the RePLAYER™ Renewable Plastics Layer System, an initiative designed to recover film waste generated by flexible packaging converters. This system focuses on removing any ink from the collected waste, pelletizing the remaining material, and converting those pellets into new flexible packaging film. Following this launch, discussions commenced in December 2022 between TOPPAN, RM Tohcello, and Mitsui Chemicals to establish a framework for a joint pilot testing project.

Fiscal 2023 marked the start of comprehensive joint pilot testing. The companies have since confirmed that the recycled film is suitable for mass production processes, including printing, laminating, and pouch forming. They have also evaluated its physical properties, such as seal strength and tear resistance in pouch form. With these validations completed, the companies are now poised to begin providing sample pouches made from the recycled materials.

Through this pilot testing project, TOPPAN, RM Tohcello, and Mitsui Chemicals have created a robust technological and operational framework for the horizontal recycling of flexible packaging film. The companies are optimistic about introducing their new material into the market by fiscal 2025, with a focus on further advancing and popularizing the horizontal recycling process for flexible packaging film. This initiative aims to not only enhance sustainability in the industry but also contribute to the broader goal of reducing plastic waste in society.