Are there any initial results you can report on?

Dr. Anna Kerps: We (employees of Fraunhofer UMSICHT) have carried out extensive research into current sorting technology in Germany. We noticed that there are some major differences in plant capacities and technology. For example, studies indicate that currently only around 19% of all plants can sort black plastics. Polystyrene as a mono-fraction is also not separated as a separate fraction in all plants. The reasons for this are, of course, that the plants have been in operation for many years and are not all state of the art. This is of course a major challenge for a uniform investigation of potential improvements in collection and sorting.

How are you dealing with this challenge in the project?

Dr. Anna Kerps: We have systematically recorded these challenges and then evaluated them with the project partners. Our Syschemiq team of experts then developed a top 10 list of ideas on how to improve the collection, sorting and pre-treatment of plastics. Examples include improving the separation and identification of black plastics, improved waste collection systems in the trilateral region, new analysis techniques at local waste collection points or the integration of AI technologies in sorting to improve the quality of the recycling input. These ideas will be fed into further work packages, which will deal with the design and development of a new sorting plant, for example.

What do the collection and sorting systems for packaging actually look like in the three countries?

Dr. Anna Kerps: If we look beyond the borders of the trilateral region, the collection and sorting practices are sometimes even more different than within Germany. In all three countries mentioned - Germany, the Netherlands and Belgium - there is an extended producer responsibility (EPR) system for household waste. These systems oblige manufacturers and importers of packaging to bear the costs of collecting, sorting and recycling the packaging. While there are various organizations responsible for products (the dual systems) in Germany that compete for market share, there is only one responsible organization for household waste in the Netherlands and Belgium. The household waste collection systems in Belgium and Germany are very uniform, whereas in the Netherlands they are highly fragmented and vary locally. This means that in the Netherlands, collection at source and/or after separation is different in each municipality. Both Germany and the Netherlands use deposit systems for PET bottles and metal cans. The system in Germany is the most advanced and also includes single-use plastic packaging for drinks. There is no such system in Belgium, but the introduction of a PET deposit system is being discussed, possibly to be introduced in 2025. In terms of commercial and industrial waste, Belgium is the only country in the trilateral region that has introduced an EPR system.

The continuous development within the sorting of packaging waste has led to ever more advanced technologies in all three countries, which are increasingly automated and operate with higher speed and accuracy. This results in higher volumes and yields of sorted packaging waste, which can be processed into higher quality streams with greater efficiency. Looking at the three regions, Belgium still lags a little behind in terms of sorting capacity. However, capacity has been increased in recent years through the construction of five new plants with state-of-the-art equipment.

What are you doing to raise public awareness of recycling concepts?

Dr. Anna Kerps: The correct collection and sorting of packaging waste starts with consumers. Only if they pre-sort some of the waste correctly, i.e. break it down into recyclable components, for example completely removing the aluminum lid from the yogurt cup from the plastic cup, can it be collected separately in the sorting plants with a high probability and assigned to the correct fractions. In the "City and Learning Labs" work package (community-based engagement programmes), a knowledge base is being created to facilitate the mobilization of citizens. Awareness-raising programs for environmentally conscious consumers are intended to increase awareness of the correct separation and collection of plastics.

On the other hand, we are working on new design-for-recycling concepts in another work package. The focus is on the development of packaging solutions that are not only innovative but also sustainable and facilitate subsequent recycling through the right design. Let's stay with the plastic yoghurt pot with an aluminum lid: we are developing and investigating ways to replace these aluminum lids with a plastic lid made of the same material as the pot. In this way, the cup and lid can be disposed of, sorted and recycled together.

What challenges arise for design for recycling and for the corresponding life cycle assessments?

Dr. Anna Kerps: The basic comparative variable in every life cycle assessment is the functional unit. All environmental impacts are related to this variable. To avoid comparing apples with pears, we must always check whether design changes also lead to changes in the functional properties of packaging. For example, if the shelf life of the product deteriorates as a result of a recycling-friendly design, this can lead to food losses. Even if our focus is on packaging, we should always avoid food loss, as this generally has a significantly higher environmental impact. Packaging must first and foremost fulfill its protective function, e.g. against spoilage. We must therefore always keep an eye on the overall system and consider possible negative interactions.

Which next steps are planned?

Dr. Anna Kerps: At the end of the project, the aim is to demonstrate a complete systemic demonstration of holistic improved plastics recycling in the trilateral region. Through the multi-stakeholder approach, we cover the entire value chain and thus create a basis that can also be transferred to other regions in Europe. The project is already showing that the networking of the partners in the project is beginning to bear fruit. The annual meetings of the entire consortium are always my highlight of the project. The atmosphere there is simply great, because everyone has a common goal and national borders don't matter.