What Is PCR Plastic? The Pros & Cons of PCR Packaging

PCR, short for post-consumer resin (or post-consumer recycled), is an environment-friendly packaging option that is made from recycled plastics. Instead of being sent to a local landfill, used items such as bottles, milk jugs, buckets, and industrial products like IBC totes and polydrums can be broken down, melted and reconstructed to make a resin material that’s then added to create a new product—PCR packaging.

PCR packaging is used to propel a continuous cycle of creating various "new" products with used recycled plastics. In addition, according to the United States Environmental Protection Agency (EPA), post-consumer recycled production reduces the reliance on fossil fuels as well as raw materials for its formulation in comparison to virgin resin products.

PCR material is made through a process that involves collecting used plastic items, sorting them by type and color, cleaning them, and then shredding them into small pieces. From there, the small plastic pieces are melted into small pellets which can be used to manufacture new products such as packaging.

Popular PCR materials include recycled plastics like polyethylene terephthalate (PET), commonly sourced from beverage bottles, and high density polyethylene (HDPE), often from milk jugs and detergent containers.

PCR can be used for anything from packaging and textiles to construction materials and consumer goods. While not all PCR is approved for food contact, certain types are processed to meet safety standards. The Cary Company offers a variety of PCR packaging including bottles, tight head containers, trigger sprayers, and drums.

Virgin resin is the term for new and unused plastic resin without any recycled products to generate an original product. Due to its clean appearance and stable nature, virgin resin is heavily used to produce a wide variety of plastic products.

PCR packaging offers a great way to reduce environmental impact. From waste reduction to brand loyalty, the benefits of PCR packaging make it a smart choice for both businesses and the environment.

Recycled resin cuts landfill waste and fossil fuel use, improving plastic packaing's environmental impact. PCR packaging appeals to eco-conscious buyers. Studies show that Gen Z and millennials, in particular, aim to help the planet through smarter buys and better habits, indicating that PCR plastics are the way of the future.

PCR plastics decrease carbon footprint, or the total amount of greenhouse gases produced by manufacturing, transportation, and disposal processes. This is because recycling used plastic requires significantly less energy than extracting and processing raw materials needed for virgin plastics.

A circular economy is a system based on the reuse of materials or products to minimize environmental impact. Using PCR plastic helps support a circular economy by reducing reliance on virgin plastics, diverting waste from landfills, and lowering energy consumption and carbon emissions associated with plastic production.

Brands can benefit greatly from using PCR packaging. As more consumers start to look for sustainable brands, using PCR appeals to eco-conscious customers and demonstrates a commitment to environmental responsibility.

PCR packaging can be suitable for food-contact use if it meets the FDA Guidelines. This includes undergoing a strict purification process to ensure the plastic is safe and free of contaminantes for food contact.

While PCR packaging offers clear environmental benefits, it also comes with a few challenges that brands need to consider. These factors can impact cost, availability, and product color. Understanding these challenges is key to making informed packaging choices.

The environmental benefits of PCR plastic rely on consumers recycling their products. Without consistent recycling, there is not enough material to produce PCR plastic, limiting its potential to reduce waste and lower carbon emissions.

The demand for PCR products is continuously growing, but there is not always enough high-quality PCR available. Since PCR production depends on consistent recycling, this can make it challenging for businesses to regularly source the containers they need.

The price of manufacturing is contingent on the amount of plastics recycled. As demand for sustainable materials grows, limited supply of recycled plastics can make PCR options more expensive than virgin alternatives.

The required reheating process in creating PCR plastics can alter the color and clarity of the plastic.  Depending on the amount of PCR added to a product, PCR packaging may have an off-white or less than clear hue. This does not hinder the function or durability of the bottle. Although manufacturers may shy away from using post-consumer resin because the slightly off-color properties do not fit the aesthetic they want to portray for their packaging, dyes can be added to conceal color inconsistencies and maintain visual consistency.

PCR carries potential contamination risks from its previous use, such as residue from food, chemicals, or non-food substances that may get into the new products. However, developing processes are making food-grade PCR possible! To ensure compliance and consumer safety, manufacturers must guarantee the plastic is clean, safe, and approved for its intended use. This may include food contact, personal care, household chemicals, or industrial applications.

After consumers recycle their products, recycling plants sort the bottles according to their plastic type. Because PET and HDPE plastics are most commonly used to manufacture PCR products, these plastics are collected, washed, and broken down into resin pellets. The resulting pellets are then reheated, molded and formed into new plastic containers.

PCR can be added in percentages ranging from 10% to 100% along with virgin plastic depending on the manufacturer's preference.

If post consumer resin is used to manufacture a plastic bottle, a higher percentage can impact transparency and color. Some companies choose to incorporate less PCR in their products and more virgin resin so the material can retain the look of virgin resin. For example, if a product is composed of 25% PCR and 75% virgin resin material, then the product will look more like a virgin bottle. Additionally, many PCR plastic bottles are typically intended for products that do not require transparent packaging.

PIR, or post-industrial resin, is reworked plastic produced in the manufacturing process. PIR consists of grinded resins that were collected either from extra scrap parts during the molding stage of production or finished products that did not pass the quality control standards of the original product. Despite never being used before, the material is not considered virgin because it has been put through a second reheating process.

PIR products have not reached the consumer whereas PCR products include used material that's already reached the consumer and returned.

While PIR is reprocessed resin, PCR is made of used and recycled resin. Much like PCR packaging, PIR also helps decrease the amount of plastic sent to landfills as well as reduce the demand for raw materials.

The term biodegradable is defined as the length of time it takes for plastic to fully break down and degrade by the consumption of living microorganisms such as fungi and bacteria. While PCR is a more environmentally friendly option (in comparison to virgin resin) since it's made from recycled plastic, according to The Federal Trade Commission's Green Guides, the plastic itself is not biodegradable unless it is decomposed within a year of being disposed of in landfills, incinerators and recycling plants.

We understand how important it is to choose sustainable, high-performing solutions. That’s why we offer a wide selection of PCR packaging designed to meet your environmental goals without compromising on quality.

If you wish to explore other eco-friendly packaging alternatives, our packaging experts can assist with finding the best product to meet your requirements. Give us a call at 630-629-6600 or email us at sales@thecarycompany.com!