Smart solutions for packaging circularity: innovations in collection and sorting

Enhancing recycling rates has been a priority for the fibre-based industry for years now, mirroring wider global efforts to optimise resources and transition to a circular economic model. In that pursuit, innovation has proven to be a trusty sidekick.

Take the example of 4evergreen, a cross-industry alliance dedicated to the cause of achieving a 90% recycling rate for fibre-based packaging by 2030. 4evergreen places research and innovation at the core of its activities, spearheading projects that explore novel recycling technologies and explore ‘sortability’ challenges.

Collection and sorting continue to take a prominent space in all discussions on how to enhance quality recycling. This essential step of the renewable packaging lifecycle plays a crucial role in ensuring that materials are diverted from landfills and kept in material loops to get recycled over and over. When paired with innovative projects like those championed by 4evergreen, these vital components of the recycling chain deliver promising prospects for fibre-based packaging circularity.

Here are some innovative examples:

1. AI-Powered Sorting

One of the most exciting innovations in the realm of collection and sorting is the integration of artificial intelligence (AI). ?Using advanced computer vision and machine learning algorithms, AI-powered sorting systems can identify and sort various paper and board grades with remarkable precision. Through complex vision systems, materials can be sorted at a superhuman speed.

For example, as materials pass through a conveyor belt, AI algorithms can learn to distinguish between corrugated cardboard, office paper and liquid cartons. This not only optimises sorting accuracy but also significantly reduces contamination, ensuring that each material stream remains pure and valuable. Preserving the purity of materials is indispensable in a high-quality recycling system in which materials are kept in circulation for as long as possible—therefore reducing dependency on newly sourced fibres or other components.

2. QR Codes

QR codes have emerged as powerful tools to bridge the gap between consumers and best recycling practices. These scannable codes, prominently displayed on packaging products, empower users to make informed decisions when disposing of them. By simply scanning the QR code with a smartphone or a dedicated recycling app, consumers receive valuable information about the item they are discarding.

This information can include guidance on which recycling stream to place the item in, details on the recycling process, and even suggestions for repurposing the product. QR codes not only encourage responsible disposal but also empower consumers. By having all the necessary information, they get to be active participants in the collective journey to a greener future.

A good example of this is what the company Mondélez International has been testing in the UK through their ‘Snacking Right’ pilot: the QR codes on their snack boxes redirect consumers to the Snacking Made Right website; the platform provides recycling information, including a map (‘Recycle Now’) to help them find their closest packaging recycling location.

3. Digital Watermarks

These unique identifiers, discreetly integrated into packaging during manufacturing, serve as silent guides for automated sorting systems. Unlike QR codes or visible labels, digital watermarks are hidden from the naked eye but reveal essential information when scanned by specialised equipment at recycling facilities.

Digital watermarks carry crucial data such as the composition of the packaging material, recycling instructions, and even product origin. Sorting equipment uses this information to precisely direct materials into their appropriate streams. This innovation simplifies the sorting process and ensures the highest quality and yield of recovered materials, ultimately contributing to the sustainability goals of reducing waste and conserving resources.

The HolyGrail 2.0 initiative, driven by AIM (the European Brands Association), is a pilot project conducted in the EU to assess both the technical and economic viability of digital watermarks for accurate sorting of packaging waste.

4. Smart Bins

In the age of smart technology, even bins are getting an intelligence upgrade. Smart bins, equipped with sensors and connected to a central database, are transforming waste collection. Beyond their role in guiding users to sort materials correctly, these bins are helping waste management teams optimise their routes and save fuel.

The environmental advantages of smart bins align seamlessly with the sustainability ethos of fibre-based packaging, widely recognised as a low-carbon alternative to fossil-based materials and their associated emissions.

Smart bins can communicate real-time data on their fill levels to collection trucks. This information allows waste collection services to prioritise bins that are nearing capacity, minimising unnecessary stops and reducing fuel consumption and emissions.

In this way, the integration of smart bins into the recycling ecosystem not only enhances the efficiency of waste collection but also aligns with the principles of fibre-based packaging, creating a responsible approach to waste management that can support Europe in advancing the low-carbon economy.

European cities have been trialling smart sensors for years. One of the most recent cases is Madrid, which, with the deployment of 11,000 sensors in collaboration with Sensoneo, is set to become the capital with the largest smart waste project in Europe.?

Innovation at every step of the packaging lifecycle

From design to collection and sorting to recycling, innovative approaches are helping the industry drive circularity every step of the way. These breakthroughs are more than just simple advancements; they reflect the value chain's commitment to respond to emerging challenges and be a strategic contributor to Europe's new economy.

When applied to collection and sorting processes, whether with the use of AI, codes or smart bins, innovation is serving to enhance efficiency and pave the way for a world where the circular economy is a reality. This collective effort promises a greener and prosperous legacy for future generations.