Waste volumes are increasing, natural resources are limited and the environment is facing major challenges. Recycling is an important part of the solution – but where do we actually stand? On Global Recycling Day, 18 March, we take a closer look at the progress, challenges, and necessary changes within the plastics industry.
Why Global Recycling Day Matters
Each year on 18 March, Global Recycling Day brings the topic of the circular economy into focus. The aim is to raise awareness of the importance of recycling and to promote innovation in this field. This is particularly relevant in the plastics industry. However, challenges remain:
The quality of recyclates is often insufficient for high-value applications. Many products require pristine materials, yet recycled plastics still have some deficiencies. Inefficient collection systems make it difficult to separate valuable materials cleanly. Different standards and a lack of infrastructure hinder the optimal reintegration of plastics into the production cycle. The economic factor also remains an issue: As long as virgin material is cheaper than recyclates, many companies opt against using recycled materials.
Technological Advances in Recycling
Modern technologies are driving forward plastic recycling, improving efficiency and quality. Three key areas hold particular promise:
Artificial Intelligence & Automation
AI improves the sorting of plastics and increases the quality of recycled materials. Copyright: Steinert
Advanced sorting facilities use AI to identify and separate plastics more precisely and efficiently. “New sorting applications are made possible, and existing ones can be carried out with greater reliability,” explains Michael Köster, Sales Manager Waste Recycling Division at STEINERT GmbH in an interview with K-Mag.
AI-supported recycling software analyses and optimises sorting processes in real time. Copyright: PolyPerception
Companies like PolyPerception are also leveraging AI to optimise sorting processes: “Our systems enable 24/7 monitoring of output stream purity, significantly improving efficiency and regulatory compliance,” says co-founder Parshva Mehta. A practical example is the waste management company Indaver in Belgium, which employs AI-driven systems to significantly increase the recovery rate of plastic packaging.
Material Innovations & Closed-Loop Systems
New technologies make it possible to recycle multilayer packaging that was previously difficult to utilise. Copyright: Krones
Companies are working on new materials and closed-loop processes to enhance recyclability from the outset. One example is a newly developed laminating adhesive that, for the first time, allows for effective material separation during recycling, recovering valuable PET fractions.
Closed loops allow recycled plastics to flow directly into new products. Copyright: HolyPoly
HolyPoly follows a holistic approach with its Closed-Loop Factory, incorporating recycling considerations right from the design phase.
Digital Tools for Material Use Optimisation
Digital tools such as the CYCLOPS tool create transparency in the circular economy and support companies in making sustainable decisions. Copyright: SKZ
Digital platforms enhance transparency in material flows and improve recycling efficiency. The CYCLOPS tool provides companies with detailed data on recycled materials, aiding in more sustainable decision-making. “Digitisation is key to restoring the often-disrupted flow of information between circular economy stakeholders,” explains Dr Jan Werner from SKZ in a K-Mag interview.
These advancements show that recycling is more than just a collection and processing procedure – it requires the seamless integration of technology, design, and digital infrastructure.
Chemical vs. Mechanical Recycling: Complementary or Competitive?
Chemical and mechanical recycling can turn plastic waste into valuable raw materials for industry. Copyright: SÜDPACK
Recycling is a crucial pillar of the circular economy – but which method is the right one? While mechanical recycling remains a well-established process, chemical recycling is gaining importance. Both methods have their strengths and challenges and should ideally be seen as complementary rather than competitive.
“This is not an either/or decision; it’s always a both/and approach,” stresses Prof Dr Manfred Renner from Fraunhofer UMSICHT.
Companies like OMV and the start-up Cyclize are investing in chemical recycling plants. Cyclize employs a plasma-based process that converts plastic waste into valuable syngas, providing a sustainable alternative to fossil raw materials. Meanwhile, Michael Ludden, Managing Director of Sutco Recycling GmbH, warns that chemical recycling should not displace mechanical processes: “If chemical recyclers start using materials that mechanical recyclers can process well, it will lead to a cannibalisation of material streams – and that must be avoided.”
Each method has its specific applications: Mechanical recycling is particularly suitable for clean, single-type plastic waste, whereas chemical recycling offers a solution for hard-to-recycle, contaminated, or complex plastic mixtures.
Remaining Challenges – and What Needs to Change
Plastic waste is a valuable resource – if recycling processes are organised efficiently. Copyright: gavran333 – stock.adobe.com
Despite technological progress, major challenges persist:
Economic Barriers: Recyclates are often more expensive than virgin materials, making them unattractive for companies. Higher costs arise from complex sorting and cleaning processes as well as limited availability of high-quality recyclates.
Regulatory Uncertainty: Many regions lack uniform legal frameworks, hindering long-term investments in recycling technologies. “If established value chains are to be successfully transformed into a functioning circular economy, clear political guidelines are essential,” emphasises Prof Dr Manfred Renner.
Technological Limits of Mechanical Recycling: While mechanical recycling allows for direct reuse of plastics, material quality and application possibilities are often limited. “Mechanical recycling has its limits: The quality of materials and the usability of recovered resources decrease over time – downcycling cannot be repeated indefinitely,” explains Dirk Hardow from SÜDPACK in an exclusive interview.
Improving Sorting Processes: New sensor technologies enable more precise polymer sorting and can significantly increase recycling rates. Significant progress has already been made in recovering plastics from electronic waste through improved identification methods. The SpecReK project by BASF demonstrates that spectroscopic measurement techniques combined with AI can significantly improve the quality of mechanically recycled plastics.
Lack of Economic Incentives: The market for recycled plastics could be boosted through targeted funding programmes and legally mandated recyclate quotas. Such measures would encourage companies to increasingly use recycled materials and invest in relevant technologies.
A functioning circular economy requires cooperation between industry, politics and consumers. Copyright: afotostock – stock.adobe.com
Recycling as a Collective Effort
Global Recycling Day serves as a reminder that recycling alone is not enough – a functioning circular economy requires collaboration between industry, policymakers, and consumers. Companies must invest more in innovative recycling technologies, while policymakers should establish clear legal frameworks and financial incentives. Consumers also have a role to play: Making more conscious purchasing decisions and improving waste separation significantly contribute to success. Only if all stakeholders work together can recycling become a true success story.
