--- title: "Plastic film packaging faces recycling challenges worldwide" url: https://newscentral.site/plastic-film-packaging-faces-recycling-challenges-worldwide/ language: en publisher: "News Central Site" section: "Science" published: 2026-10-16T15:00:08.000Z updated: 2026-10-17T09:52:09.974Z id: b40b55e2-a51b-4dc6-984b-cd2b113422b9 source: "Phys.org https://phys.org/news/2026-10-plastic-packaging-purpose-wont-recycling.html" attribution: "Link to https://newscentral.site/plastic-film-packaging-faces-recycling-challenges-worldwide/ and name News Central Site when you quote or summarize this story." --- # Plastic film packaging faces recycling challenges worldwide A chemical company in northeast England has received planning approval to build what it claims will be the UK's first large-scale plant for processing plastic film waste. Plastic film packaging is notoriously difficult to recycle, and this issue affects many households worldwide. The flimsy wrapping paper that covers microwave meals or bread bags is often discarded without much thought for its recyclability. However, a closer look at the potential uses of these hard-to-recycle plastics reveals an interesting opportunity. In theory, plastic film could be transformed into fuel, offering a novel solution to waste management and energy needs. But current recycling laws in the UK present a significant hurdle for companies seeking to innovate in this area. The problem lies in the definition of recycling itself, which is governed by strict regulations under U.K. waste law. The existing rules define recycling as the process of converting waste into new products, not fuel. This narrow interpretation prevents companies from exploring alternative uses for hard-to-recycle plastics, such as turning them into fuel to reduce reliance on imported energy sources. The definition of recycling needs to be reevaluated to accommodate emerging technologies and innovative approaches to waste management. By broadening the scope of what is considered recyclable, policymakers can unlock new opportunities for companies to experiment with creative solutions to plastic waste disposal. A chemical recycling company in northeast England has received planning approval to build what it claims will be the UK's first large-scale plant for processing plastic film waste. The facility, operated by Endolys, aims to process up to 120,000 tonnes of plastic film annually, including items such as bread bags and wrappers. The plant uses a process called pyrolysis, where plastic is heated to extremely high temperatures in the absence of oxygen. This prevents combustion, causing the plastic to break down into pyrolysis oil, along with some gas and solid residue. The result is similar to making charcoal by heating wood without allowing it to catch fire. The success of this method has been mixed globally. In Texas, ExxonMobil processes over 70,000 tonnes of plastic waste annually using pyrolysis. However, a Rotterdam plant in the Netherlands that was contracted to supply Shell failed to reach its intended capacity and has since shut down permanently. The oil extracted from plastic waste through pyrolysis is not suitable for direct use as diesel fuel. Instead, it resembles crude oil in composition and requires extensive processing before it can be used as a fuel source or raw material for producing new plastics. This refined oil will be sold to a global trader who supplies European refineries, but this arrangement has implications for the UK's energy security. For a plant to contribute significantly to the country's fuel supply, the oil would need to remain within national borders. The production of pyrolysis oil is expected to reach around 80,000 tonnes annually at the Darlington facility. This process involves heating plastic waste in the absence of air, which reduces the formation of toxic chemicals that can be produced when plastic is burned. Studies have shown that burning plastic can release dioxins, a group of chemicals linked to cancer risks. While modern incinerators are designed to minimize these emissions and meet strict standards, alternative methods like pyrolysis may offer a safer approach by producing fewer hazardous substances. A recent German study suggests that converting plastic into oil could significantly reduce greenhouse gas emissions associated with waste management. The research indicates that this method can cut emissions by more than half and potentially up to 94% as electricity production becomes cleaner in Germany. However, pyrolysis plants face a challenge in their operation, as they often burn some of their own gas to maintain functionality, which is subject to similar regulations as incinerators. The process also generates contaminants such as inks, food residue, and chlorine from certain plastics that must be removed from the resulting oil. These contaminants can still pose environmental risks when the final product is burned as fuel, releasing pollution and carbon emissions into the atmosphere. In some areas, concerns over public health have prompted residents to voice opposition to pyrolysis plants, highlighting the need for careful consideration of waste management strategies. Local authorities in England had planned to begin collecting plastic film from households by 2030, following an initial target set for 2027 that was subsequently delayed. The delay is partly due to a lack of infrastructure capable of processing this specific type of plastic, which remains one of the most difficult materials to recycle effectively. The current recycling laws in the UK fail to incentivize plants like Darlington to sell their oil domestically, resulting in the energy security benefits being lost elsewhere. Darlington's annual production of 80,000 tonnes of oil is a significant amount, but it still only accounts for a tiny fraction of the country's overall oil needs. In 2025, the UK used around 61 million tonnes of oil products, and Darlington's output would meet just 0.1% of that demand. England generates an enormous amount of plastic waste every year, with approximately 4.2 million tonnes entering landfills annually. If half of this plastic were converted into oil at Darlington's rate, it could potentially meet around 2% of the UK's oil needs. With the right regulations in place, a steady supply of domestically produced oil from recycled plastics could help reduce the country's reliance on imported oil and mitigate the impact of future fuel shortages. This is a promising idea that warrants further exploration. The potential for recycling plastic waste into oil is substantial, especially when considering the sheer volume of plastic waste generated in England each year. By exploring this option, policymakers may be able to create a more sustainable energy landscape for the UK. The UK's current recycling laws may not be allowing for the full potential of plastic film packaging to be utilized as a valuable resource. By exploring alternative uses for this material, policymakers can potentially create a more sustainable energy landscape for the country. This approach could involve rethinking how plastic films are collected and processed, with an eye towards extracting their maximum value. --- Source: [Phys.org](https://phys.org/news/2026-10-plastic-packaging-purpose-wont-recycling.html) Published by News Central Site: https://newscentral.site/plastic-film-packaging-faces-recycling-challenges-worldwide/