A decade of development work has led to what Pact Recycling NZ says is a significant step forward in the recycling of one of the most difficult packaging waste streams – mixed polymer post-consumer soft plastics.
Working with the Soft Plastics Recycling Scheme and The Packaging Forum, Pact Recycling NZ has successfully processed mixed polymer soft plastics through its upgraded wash plant at East Tamaki, converting the material into products including underground cable cover and plastic plywood.
The feedstock is collected through New Zealand's retail soft plastics collection network, including supermarket drop-off points, before being washed, reprocessed and remanufactured.
Mixed polymer soft plastics – including items such as foil-lined snack packets, multilayer food pouches and plastic bags – have traditionally been difficult to recycle because they combine multiple plastic types in a single structure, making conventional mechanical recycling challenging.
An initial 5000kg trial delivered a material yield of around 72 per cent, which Pact says is comparable with some post-consumer material processed through conventional material recovery facilities. Based on those results, the company has commenced a three-month trial processing around 20,000kg of material each month during July, August and September.
The project has been supported by investment from both Pact and New Zealand's Waste Minimisation Fund.
According to Pact, the products manufactured are made from 100 per cent recycled plastic. The mixed polymer soft plastics currently represent a proportion of that recycled content, with the trial intended to determine how much of the stream can be incorporated while maintaining product performance.
Steve Mead, general manager of Pact Recycling NZ, said the project demonstrates the value of long-term investment in recycling infrastructure.
"For years, mixed polymer soft plastics have been one of the most challenging materials to recycle and use at scale. This trial demonstrates what can be achieved when industry collaboration is backed by the right infrastructure and technical expertise," Mead said.
"We're not just proving that post-consumer mixed polymer soft plastics can be recycled, we're showing how they can be transformed into durable products that create real value and help strengthen New Zealand's circular economy."
Lyn Mayes, representing The Packaging Forum, said the milestone reflected more than a decade of development.
"This story culminates more than 10 years of Pact Recycling innovating our technology and plant to find a solution for post-consumer soft plastics."
The trial represents another example of how investment in collection systems, processing infrastructure and end-market development is helping expand the range of plastic packaging materials that can be recycled. While the current program is focused on durable construction products rather than closed-loop packaging applications, it demonstrates a practical pathway for recovering value from a waste stream that has historically been destined for landfill.
