National Plastics Recycling Survey 2015

Summary for publication

Published May 2016

Information provided in good faith May 2016 - Plastics|SA - Media

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INTRODUCTION
Early in 2014, the plastics fraternity agreed that the aspirational vision of Zero Plastics to
Landfill by 2030 can be achieved if all the polymer groups, industry associations and
recyclers work together.
Where is the industry currently?
Plastics|SA had, over the last couple of decades, measured the recycling rate of plastics in
South Africa. The last comprehensive and complete survey was done for 2014. Annual
updates are done to measure the trends in recycling. This report is for the recycling rates of
2015.

KEY FINDINGS
South Africa mechanically recycled 292 917 tons of plastics in 2015 an increase of
3 % from 2014.
Over the last 5 years the compounded growth in plastics recycling was 5.5 % per
annum.
Domestic production of virgin polymers totalled 1 490 000 tons in 2015, growing 6,4 %
from 2014. This growth would essentially be as a result of the weakening exchange
rate against international currencies that lead to local procurement of plastics products
rather than imports.
A total of 310 641 tons of plastics were diverted from landfill in 2015. This is 1.6 %
less than in 2014 and is due to the significant reduction in the export of recyclable
waste.
The overall diversion from landfill rate was 20.8 % - decreasing from 22.5 % in 2014.
Strong growth was seen in the recycling of PET, PE-LD/LLD and PS due to new
capacities that came on line in 2015.
Recycling rates of PE-HD, PP and PVC declined as some of the products traditionally
made from recyclate of these materials are directly linked to consumer spending and
mining activities.
Formal employment increased with 3.3 % to 6234 permanent jobs.
Informal jobs has grown with 3 % to an estimated 48 820 collectors.
The recycling industry invested 48 % more in capital equipment per ton of material
processed in 2015 to deal with increasing demands and improved quality requirements.
Processing costs increased 15.4 % year on year with the biggest contributors to cost
being water, electricity and transport.

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Divers
Tonnages
ion from
recycled
landfill rate

Figure 1: Tonnages recycled and diverted from landfill in South Africa for the last five years all plastics

Table 1: Annual South African consumption and recycling for the last five years

2011
Total tons converted

2012

2013

2014

2015

1 300 000

1 370 000

1 400 000

1 400 000

1 490 000

-1,0%

5,4%

2,2%

0,0%

6,4%

230 111

254 054

260 930

284 521

292 917

0,9%

10,4%

2,7%

9,0%

3,0%

Recycling rate

17,7%

18,5%

18,6%

20,3%

19,7%

Waste exported

9 758

14 744

18 919

31 087

17 724

% growth (waste exported)

7,8%

51,1%

28,3%

64,3%

-43,0%

239 869

268 798

279 849

315 607

310 641

18,5%

19,6%

20,0%

22,5%

20,8%

Tonnages landfilled

1 060 131

1 101 202

1 120 151

1 084 393

1 180 459

% growth (landfill)

-1,4%

3,9%

1,7%

-3,2%

8,7%

% growth (conversion)
Total tons locally recycled
% growth (recycled)

Total tons diverted from landfill

Diversion from landfill

DIVERSION FROM LANDFILL

Many plastics products are used in our daily lives. Some are used for a short period like
food packaging and are discarded into the waste stream once it fulfilled its role of protection
or containment. Other products are discarded when the consumer has used it for a specific
function or when the product is broken, obsolete or have reached the end of its life. These
could include products like stationery items, calculators, office furniture or toys. Then there
are plastics products that are functional for long periods and only get discarded into the
waste stream after 5 or 10 years. Things like gutters and carpeting can be used for decades.
South Africa, like the rest of the world, discard most of its waste to landfill where it is
covered with soil and forgotten about. As consumers consume more and more, sufficient
space to landfill our waste, is becoming more of a challenge. Diversion from landfill is the
only solution. What can be done with waste instead of putting it on landfills?
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The most energy

its active role, i.e.
packaging is reeven shopping
functional.
Mechanical
as long as
typically used in
potential life of
perceived value is
recyclate is used
products are
although the
lived packaging
economically
Pyrolysis is
access the fuel
plants are using
crude oil, diesel,
are hard to come
in most cases.
layer packaging
polyolefins, are

efficient way is to return the product to

re-use. Substantial quantities of
used daily. Crates, drums, pallets and
bags, are re-used till no longer
PE-HD milk bottles used for
1 week

PE-HD milk bottles recycled into

ride-ons - used for 3 years

PE-HD ride-ons recycled into

irrigation pipe used for 5 years

Incineration, or
volumes of mixed
municipal waste
handling in
Recyclable,
of the developing
virgin plastics.
from landfill was
these, 78.8 %
substantially less
Chinese growth
for recyclable

recycling is keeping plastics plastic for

possible. Domestic recyclate is
100 % recycled products and the
the product is extended but the
reduced in the process. Where
as virgin replacement in small dosages,
perceived as maintaining its value,
applications would be into other shortitems. Mechanical recycling is only
viable in large volumes.
slowly developing in South Africa to
value of the discarded products. Trial
tyres as well as plastics to generate
gas and carbon black. Official statistics
by as the plants are only experimental
Polyolefins, mixed materials and multifilms that contain predominantly
suitable for pyrolysis.
energy recovery, is popular for large
waste in developed countries. Solid
can be used, no sorting and very little
general is required.

Irrigation pipe recycled with

other polyolefins into polywood
for benches used for 20 years

Benches could be used in

pyrolysis or other energy
harvesting processes at the end
of its life of approximately
28 years
Figure 2: Illustration of a typical
PE-HD mechanical recycling value
chain

sorted plastics are sought after in many

countries as a cheaper replacement for
Only 5.7 % of all the plastics diverted
exported for recycling elsewhere. Of
went to China and Hong Kong. This is
than in 2014. The slow-down in the
rate has a direct impact on the demand
waste.

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South Africa measures diversion from landfill and achieved a 20.8 % diversion rate in 2015.
Of all the plastics manufactured in 2015, just over 20 % did not go to landfill.

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POLYMERS RECYCLED
The single biggest challenge of plastics recyclers in 2015 was the lack of a consistent
incoming stream of recyclables. Available materials was of very poor quality and scrap levels
of 35 to 40 % was experienced in the Northern provinces where demand for recyclable
materials exceed supply. Export markets declined and more material become available to the
local recyclers but with no improvement in the quality.
The waste pickers only pick the materials for which they have a known market. There is
limited direct communication between the recycler and the waste picker. There may be a
huge demand for injection moulding PP, but the waste picker is not necessarily aware of a
market for dairy packaging. As a result, perfectly good packaging items remain in the solid
waste instead of being recycled.
On the other hand, very little development work is done to recycle and supply grades required
by converters for specific applications. Due to the huge demand for recyclate, recyclers
supply the easy grades where volumes can be moved. Only during periods of diminished
demand, recyclers focus on the less common potential markets. Normally, due to the nature
120,000

100,000

80,000

Tonnages recycled

60,000

40,000

20,000

PE-LD/LLD

PE-HD

PET

PP

PVC

PS & PS-E

Other

Figure 3: Plastics Materials recycled in the last five years all materials

of the product, very little value adding is taking place during recycling.
The most recycled material is PE-LD/LLD packaging films. Recycled PE-HD crates follow
with PET beverage bottles being the third most popular material for recycling in South
Africa. PP is a mixture of packaging and non-packaging items ranging from fishing ropes,

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garden furniture to margarine tubs and closures. PVC is mainly electrical cable sheathing and
plumbing pipes.

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THE WAY FORWARD

The plastics recycling industry is under strain. There are expectations that the recycling
industry will save the planet, extent the supply of natural resources, provide cheaper raw
materials, create sustainable jobs, fix the image of plastics littering, save landfill space, clean
the country of litter and above all, to do it at no cost to no one!
Plastics recycling is a plastics manufacturing process that need to make money to be
sustainable. It needs to be economically viable. Like all manufacturing processes, challenges
need to be understood and managed. Opportunities need to be identified and utilised.
Plastics recycling is under strain. Growth is minimal. The tonnages diverted from landfill
are crawling upwards. What could, and should be done to empower recyclers?
Separation at Source
Recyclable materials need to be extracted from the waste stream earlier to limit unnecessary
contamination and reduce handling costs. Mandatory separation-at-source needs to be
implemented in metropolitan areas and larger municipalities to start with. Local government
need to see the industry as partners in saving landfill space. As a result, the perceived value
of waste will increase which will impact on litter and litter awareness.
Political will
Decision makers and legislators are not always aware of the achievements and challenges at
ground level. The plastics industry should continue to invite decision makers and legislators
to recycling plants to inform them about the intricacies of plastics recycling in South Africa.
Stakeholder commitment
Plastics converters have committed themselves to voluntary levies to encourage recycling and
create awareness through the various Extended Producer Responsibility organisations.
However, further measures are required to aid plastics recycling:

Design for recycling product design offices should include design principles at

concept stage to prevent, or at least reduce, the use of multi-layers, water insoluble
glues, excessive decoration, fillers and other additives that could alter the specific
gravity of the polymer.
Product development Sales and Marketing should find products that are suitable for
recycled content. Converters should commit to a certain percentage of recyclate in
their raw material consumption. Equipment should be selected that allow for multilayer construction to accommodate recyclate inner layers. The industry would benefit

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from a customised incentive scheme from institutions like the Industrial Development
Corporation.
Brand owner Commitment
Brand owners and retailers must get actively involved in taking care of their products, local
and imported goods. When designing products, recycling and end of life products must be
designed into the product. Manufacturers of plastics packaging produced products as per
brand owners requested designs.
Quality of Recyclables
Waste pickers, collectors and recyclers need to be educated on the various materials and basic
chemical principles that will impact on recyclate quality. Sorting processes need to be
managed better. Recyclers should communicate their requirements to their suppliers all down
the value chain to waste picker level.
Quality of Recyclate
Converters must communicate their recyclate requirements to the recycling industry.
Recyclers must invest in quality measurement and the compilation of material data sheets.
Branding of recyclate would be so much more professional. Converters must honour quality
recyclate with supply contracts and better prices.
Energy efficiency
Electricity usage is three to four times more for recyclers than convertors for the same
tonnages. Energy management must receive priority to minimise and optimise energy usage
for water and electricity. Recyclers will have to do long-term planning for increased costs
of energy and may even have to consider self-generation of energy.
Public awareness and education
The public must be educated to separate at source and to insist on recyclable packaging. The
consumer assistance in making products recyclable is essential. Consumers need to be
educated with regards the removal of shrink-labels, separation of various components and
cleaning out of residual contents, etcetera. The public must also hear about the local success
stories to be able to pride themselves in our lovely country and its achievements.
Alternate Technologies
Mechanical recycling has a ceiling. Not all materials can be recycled economically. The
plastics industry need to find some technology partners to tailor-make alternative recycling
methods to deal with plastics waste that cannot be mechanically recycled.
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The plastics recycling industry has achieved outstanding results in the bigger scheme of
things. However, continuing with business as usual is not going to meet any of the
expectations. It is now time to take plastics recycling to a totally new level.

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Appendix

DEFINITIONS
COLLECTION
The process where recyclable waste is picked from the waste stream and sorted into the
different grades. Waste pickers would be the first link in the chain. Primary collectors would
transport sorted recyclables to larger organisations. Collectors do some further sorting and
bale specific grades together in heavy compacted bales to economise transport.

CONVERTER
The plastics manufacturer that make products from virgin or recycled raw materials is called
a converter.

DIVERSION FROM LANDFILL

The waste that was destined to be landfilled that were sorted and recycled into raw materials
either locally or in another country.

RECYCLABLE WASTE
A portion of the solid waste stream that can be identified, picked, transported and
economically manufactured into a raw material again.

RECYCLATE
Raw material in flake or pellet form made from recyclable waste.

RECYCLING
Sorted waste materials are converted back into a raw material that can be used to make
another product. Example: Packaging film can be cut, washed and melted into pellets which
the refuse bag manufacturer will use to make new refuse bags.
In South Africa, all plastics recycling is currently done mechanically.

SEPARATION AT SOURCE
Waste generators and consumers separate wet waste from recyclable waste in two different
receptacles. Only the wet waste go to landfill and recyclable waste will be sorted into the
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Appendix
different material streams. Recyclable materials will remain free from unnecessary
contamination like grass clippings and animal waste.

INCINERATION
Plastics waste is burnt in a controlled environment to generate heat which can be used to
produce steam for electricity.

PYROLYSIS
Plastics waste is heated under vacuum to break it down into the basic chemical building
blocks.

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