Label selection should be considered carefully to find the solution most compatible with the recycling process that also provides the necessary performance characteristics. To be categorized as Preferred, a finished label must meet both of the following criteria:
Automated sorting performance criteria:
Surface area is defined as the area of the label divided by the area of the side wall and shoulder of the container. The area of the neck ring, threaded finish and base are not included in the area calculation. Metal decoration includes vapor deposited metal films, metal foils, or inks with metallic pigments.
Containers with no more than 55% surface area coverage by a label are expected to sort accurately in both NIR and color optical sorters. Labels with metal decoration can be tested for any impact on sorting performance using APR Test Methods.
Since labels for PET packaging most often become a waste stream, APR encourages labels that are as small in surface area and weight as possible.
Surface area is defined as the area of the label divided by the area of the side wall and shoulder of the container. The area of the neck ring, threaded finish and base are not included in the area calculation. Metal decoration includes vapor deposited metal films, metal foils, or inks with metallic pigments.
Containers with no more than 75% surface area coverage by a label are expected to sort accurately in both NIR and color optical sorters. Labels with metal decoration can be tested for any impact on sorting performance using APR Test Methods.
Since labels for PET packaging most often become a waste stream, APR encourages labels that are as small in surface area and weight as possible.
Labels will employ hot caustic resistant inks designed to be compatible with PET recycling, and float in water.
Labels containing metalized material that are below the preferred surface area per APR-RES-SORT-4.Metalized material includes vapor deposited metal films, metal foils, or inks with metallic pigments.
Polystyrene Labels that float in water per PET-S-05.While standard polystyrene has a density of > 1.0 g/cm3 and sinks, expanded polystyrene may float and be separable from the PET.
Click below for commercially available Labels that have achieved APR Design for Recyclability Recognition
APR Design® for Recyclability Recognitions
Paper labels
The PET reclamation process involves a hot caustic wash that removes adhesives and other label components. This process renders paper into a pulp which is very difficult to filter from the liquid, adding significant load to the filtering and water treatment systems. Some of the small individual paper fibers will remain with the PET and carbonize when the material is extruded, causing unacceptable quality degradation. Non-pulping paper labels that resist the caustic wash process sink in the float-sink tank, thereby causing RPET contamination.
PVC and PLA
Both materials are extremely difficult to remove in the recycling process due to their similarity in density to PET, which causes them to sink in the float/sink tank along with the PET. Both cause severe quality degradation in the final recycled PET stream even in very small amounts.
Laminated label substrate
Labels that break into small, very thin pieces of material are more difficult to manage in the recycling process because they behave erratically in a float-sink tank. Therefore, labels that stay intact are preferred. Carry-over of delaminated labels into the RPET can result in contamination.
In order for any of these label materials to be considered Preferred Design, the specific items must have been tested and found Preferred based on the test results. If these items have not been tested, they are considered Detrimental to Recycling. Testing will determine the appropriate category.
Companies that are considering such materials and are unsure of their compatibility with recycling should ask their suppliers to provide APR test results.
DEFINITIVE TEST
Labels that exceed the surface area coverage as described in Preferred Guidance section.
Labels with high surface area coverage may interfere with detection of the PET container. The label substrate (film or paper), inks, and metal decoration can interfere with NIR detection when the label covers a high surface area of the container. Also, high label surface area coverage may cause a clear PET bottle to be sorted as a colored bottle in a color sorter.
If one’s design is outside of the best practice guidance above, the labeled bottle must be evaluated using the APR test methods below.
DEFINITIVE TEST - NIR
DEFINITIVE TEST - Color
Film Labels that sink in water per PET-S-05.
Crystallizing co-polyester label films should be tested to show crystallizing behavior and show they do not cause “clumping” similar to that of amorphous PETG films.
SCREENING TEST
DEFINITIVE TEST
Olefin films that sink in water due heavy inks but float after exposure to hot caustic wash solution should be tested
SCREENING TEST
DEFINITIVE TEST
Labels containing metalized materials that are above the preferred surface area per APR-RES-SORT-4.
Labels that have surface areas above the preferred surface areas specified in the Screening Test below would need to be tested using the Benchmark Test below to verify they are under the spherical equivalent thresholds.
Metalized material includes vapor deposited metal films, metal foils, or inks with metallic pigments.
Without further testing, labels with metalized material with surface areas above the starting points in the table are categorized as detrimental due to a higher probability of being removed by the metal detector during sortation.
Solid foils will continue to render the package non-recyclable per APR’s definition.
SCREENING TEST
BENCHMARK TEST
Polystyrene labels that sink
The density of PET is 1.38 g/cm3 and so it sinks in water. Polystyrene has a density of > 1.0 g/cm3, so it sinks and remains with the PET in float/sink separation systems. It is not compatible with PET and may cause serious processing and end-use problems.
SCREENING TEST
DEFINITIVE TEST
Innovation in plastics and packaging is necessary to maintain a healthy and competitive industry. To support innovators, the APR has developed a variety of laboratory test method documents that can be used to assess the impact of a plastic design feature or component on recycling. APR test methods combine laboratory practices and measurements developed specifically by and for plastic recyclers with standard ASTM tests. The objective of testing is to determine the impact of a design feature on the processability of a package item as well as the ability of post-consumer resin (PCR) derived from such feedstocks to meet quality specifications for end-use applications. To view APR’s test method definitions, click here.
In addition, APR recommends adherence to the product stewardship considerations outlined in the PET Design Guidance. A longer-term goal at APR may be to include adherence to the product stewardship guidance when evaluating package features that meet the APR Preferred category.
ADDENDUM UPDATE
As of March 22nd, 2024 the APR Design Guidance and Guidance Table for PET have been updated with all of the addendum contents. As of this date, these addendums will no longer be available on our website. All future updates will be made directly into the APR Design Guidance and Guidance Table, eliminating the need for separate addendums.
Optical Brighteners
Optical brighteners are not removed from PET in the recycling process and the residual amount can cause unacceptable fluorescence in the next use of the PET resin. The negative impact on the value and quality of the rPET is not detectable until late in the recycling process.Optical brighteners are not removed from PET in the recycling process and the residual amount can cause unacceptable fluorescence in the next use of the PET resin. The negative impact on the value and quality of the rPET is not detectable until late in the recycling process.
“Composite Attribute Summary Score” –CASS
The CASS is an evaluation of the sorting potential of an item based on its dimensions. The guiding principle is that rigid plastic packaging articles that are more three-dimensional (round, cylindrical, square) will sort more efficiently in today’s MRFs than those which are more two-dimensional (flat). The evaluation applies a weighting factor to each dimension length, then assigns the score based on the summation of the adjusted dimensions. Depending on the CASS, an item may be classified as “Preferred”, or it may need to be tested to determine its actual sorting potential. The CASS is intended to be used with the Evaluation of 2D/3D Sorting Potential of Articlestest method which is under developmentThe CASS is an evaluation of the sorting potential of an item based on its dimensions. The guiding principle is that rigid plastic packaging articles that are more three-dimensional (round, cylindrical, square) will sort more efficiently in today’s MRFs than those which are more two-dimensional (flat). The evaluation applies a weighting factor to each dimension length, then assigns the score based on the summation of the adjusted dimensions. Depending on the CASS, an item may be classified as “Preferred”, or it may need to be tested to determine its actual sorting potential. The CASS is intended to be used with the Evaluation of 2D/3D Sorting Potential of Articlestest method which is under development
Intrinsic Viscosity
When IV of PET resin is low, PET can be brittle and create more fines when the PET is granulated and washed. Also, lower IV causes finished washed PET flake to require longer solid stating times to bring resin up to a targeted IV value required by end users. When IV is higher than stated in guidance, the IV of finished flake may become too high and the resulting high melt viscosity can interfere with molding processes.When IV of PET resin is low, PET can be brittle and create more fines when the PET is granulated and washed. Also, lower IV causes finished washed PET flake to require longer solid stating times to bring resin up to a targeted IV value required by end users. When IV is higher than stated in guidance, the IV of finished flake may become too high and the resulting high melt viscosity can interfere with molding processes.
monomer composition
A wide variety of polyester copolymers can be made commercially. A common outcome of making copolymers is that the desirable crystallinity associated with PET is substantially reduced, or even eliminated. Such copolymers may become viscous and sticky like an adhesive at temperatures used to dry recycled PET washed flake. The viscous and sticky behavior results in formation of clumps of PET flake. These clumps are highly undesirable because they can block screens in materials handling systems and can adhere to the inside of driers interfering with drier performance.A wide variety of polyester copolymers can be made commercially. A common outcome of making copolymers is that the desirable crystallinity associated with PET is substantially reduced, or even eliminated. Such copolymers may become viscous and sticky like an adhesive at temperatures used to dry recycled PET washed flake. The viscous and sticky behavior results in formation of clumps of PET flake. These clumps are highly undesirable because they can block screens in materials handling systems and can adhere to the inside of driers interfering with drier performance.
Other Transparent Colors
Other transparent colors are used for PET bottles containing specialty beverages, supplements, personal care and automotive products. These may be sorted as PET and processed into lower value, dark colored fiber or sheet products.Other transparent colors are used for PET bottles containing specialty beverages, supplements, personal care and automotive products. These may be sorted as PET and processed into lower value, dark colored fiber or sheet products.
Opaque and White
The colorants used to make a white PET bottle are not separable from the resin, and mix with clear and all other colors when the rPET pellets are extruded. This results in undesirable colors and a low-value rPET.The colorants used to make a white PET bottle are not separable from the resin, and mix with clear and all other colors when the rPET pellets are extruded. This results in undesirable colors and a low-value rPET.
Black and Dark Colors
Historically, black colored packaging items have not been detectable as PET with NIR sorting, and therefore virtually all went to the waste stream. Recent innovations in both black colorants and sortation technology have created the possibility of sortable black PET containers. However, markets for black PET containers remain limited as referenced above. Therefore, testing results are limited to Detrimental and Non-recyclable only at this point in time.Historically, black colored packaging items have not been detectable as PET with NIR sorting, and therefore virtually all went to the waste stream. Recent innovations in both black colorants and sortation technology have created the possibility of sortable black PET containers. However, markets for black PET containers remain limited as referenced above. Therefore, testing results are limited to Detrimental and Non-recyclable only at this point in time.
Large size boundary
Recycling machinery, particularly automatic sorting equipment, is not large enough to accept items larger than 7.5 liters . Because larger containers jam the systems, most MRFs employ manual sortation before the automatic line to remove the large items. These items are recovered in a stream of bulky rigid containers that are sold and processed as polyethylene since the vast majority of bulky rigid items are comprised of this polymer. Other polymers including PET either negatively affect or are lost by the polyethylene processing.Recycling machinery, particularly automatic sorting equipment, is not large enough to accept items larger than 7.5 liters . Because larger containers jam the systems, most MRFs employ manual sortation before the automatic line to remove the large items. These items are recovered in a stream of bulky rigid containers that are sold and processed as polyethylene since the vast majority of bulky rigid items are comprised of this polymer. Other polymers including PET either negatively affect or are lost by the polyethylene processing.
Closure liners that are composites of AL and Paper
These materials will contaminate wash water, will contribute to waste disposal costs, or will stick to the saleable closure material or valuable PET and reduce quality and value of the final products.These materials will contaminate wash water, will contribute to waste disposal costs, or will stick to the saleable closure material or valuable PET and reduce quality and value of the final products.
Closures & shrink film safety seals made of polymers with density > 1.0
Polystyrene, silicone, nylon, acetal, and thermoset plastics are plastics that are expected to sink in the float-sink tank with PET and be detrimental to PET recycling. Sinking plastics are not removed from PET, thereby causing contamination in the final product.Polystyrene, silicone, nylon, acetal, and thermoset plastics are plastics that are expected to sink in the float-sink tank with PET and be detrimental to PET recycling. Sinking plastics are not removed from PET, thereby causing contamination in the final product.
Nylon
Nylon barrier layers are not removed in the PET recycling process. The presence of nylon causes discoloration in the PET flake, ultimately reducing the value of the RPET produced. Compensating for the presence of nylon by using additional toners adds cost and potentially other contaminants to the recycling process.Nylon barrier layers are not removed in the PET recycling process. The presence of nylon causes discoloration in the PET flake, ultimately reducing the value of the RPET produced. Compensating for the presence of nylon by using additional toners adds cost and potentially other contaminants to the recycling process.
Recommended Barrier Materials or Additives
In order for any of these materials to be considered Preferred Design, the specific items must have been tested and found Preferred based on the test results.In order for any of these materials to be considered Preferred Design, the specific items must have been tested and found Preferred based on the test results.
Untested Barrier Materials or Additives
Barriers and additives that have not been tested under APR test protocols are classified as Detrimental due to a lack of data about their impact on the cost, productivity and quality of the PET recycling process.Barriers and additives that have not been tested under APR test protocols are classified as Detrimental due to a lack of data about their impact on the cost, productivity and quality of the PET recycling process.
Untested Additives
Barriers and additives that have not been tested under APR test protocols are classified as Detrimental due to a lack of data about their impact on the cost, productivity and quality of the PET recycling process. Toners, reheat additives and degradable additives are of particular concern to PET reclaimers.Barriers and additives that have not been tested under APR test protocols are classified as Detrimental due to a lack of data about their impact on the cost, productivity and quality of the PET recycling process. Toners, reheat additives and degradable additives are of particular concern to PET reclaimers.
Paper
The PET reclamation process involves a hot caustic wash that removes adhesives and other label components.This process renders paper into a pulp which is very difficult to filter from the liquid, adding significant load to the filtering and water treatment systems.Some of the small individual paper fibers will remain with the PET and carbonize when the material is extruded, causing unacceptable quality degradation.Non-pulping paper labels that resist the caustic wash process sink in the float-sink tank, thereby causing RPET contamination.The PET reclamation process involves a hot caustic wash that removes adhesives and other label components.This process renders paper into a pulp which is very difficult to filter from the liquid, adding significant load to the filtering and water treatment systems.Some of the small individual paper fibers will remain with the PET and carbonize when the material is extruded, causing unacceptable quality degradation.Non-pulping paper labels that resist the caustic wash process sink in the float-sink tank, thereby causing RPET contamination.
Polymers with density > 1.0, except PVC and PLA
The density of PET is 1.38 and so it sinks in water.The reclaimers rely on float-sink systems to separate non-PET materials.Label components that sink with the PET end up in the RPET stream as contaminants. PVC and PLA are unacceptable at any level.The density of PET is 1.38 and so it sinks in water.The reclaimers rely on float-sink systems to separate non-PET materials.Label components that sink with the PET end up in the RPET stream as contaminants. PVC and PLA are unacceptable at any level.
Paper
The PET recycling process involves a hot caustic wash that removes adhesives and other components. This process renders paper into a pulp which is very difficult to filter from the liquid, adding significant load to the filtering and water treatment systems. Some of the small individual paper fibers will remain with the PET and carbonize when the material is extruded, causing unacceptable quality degradation.The PET recycling process involves a hot caustic wash that removes adhesives and other components. This process renders paper into a pulp which is very difficult to filter from the liquid, adding significant load to the filtering and water treatment systems. Some of the small individual paper fibers will remain with the PET and carbonize when the material is extruded, causing unacceptable quality degradation.
Welded, regardless of resin
A certain amount of a welded attachment cannot be separated from the PET in the recycling process.These attachments, even when ground and made of floatable materials, cause RPET contamination and yield loss issues in both cases: when the PET they are attached to causes the ground section containing both polymers to sink, or when the ground section floats.A certain amount of a welded attachment cannot be separated from the PET in the recycling process.These attachments, even when ground and made of floatable materials, cause RPET contamination and yield loss issues in both cases: when the PET they are attached to causes the ground section containing both polymers to sink, or when the ground section floats.
RFID
Unless they are compatible with PET recycling and are demonstrated not to create any disposal issues based on their material content, the use of RFID’s is discouraged as it limits PET yield, introduces potential contamination, and increases separation costs.Unless they are compatible with PET recycling and are demonstrated not to create any disposal issues based on their material content, the use of RFID’s is discouraged as it limits PET yield, introduces potential contamination, and increases separation costs.
PS
Polystyrene has a density of > 1.0, so it sinks and remains with the PET in float/sink separation systems. It is not compatible with PET and may cause serious processing and end-use problems.Polystyrene has a density of > 1.0, so it sinks and remains with the PET in float/sink separation systems. It is not compatible with PET and may cause serious processing and end-use problems.
APR Recognized Commercially Available Options
FreshSafe-PET®APR Recognized Commercially Available Options
ColorMatrix Europe