A plastic colourant firm has developed technology which could save thousands of tonnes of waste from being sent to landfill.
Most black plastic used in packaging is not recycled because it cannot be identified by the near infrared detectors used at waste sorting facilities.
Despite the plastic itself being recyclable it ends up in landfill because it can not be detected.
Now Colour Tone Masterbatch, based in Bedwas in south Wales, has developed a colouring package which means manufacturers can colour their products however they want (including black) – while retaining its detectability when it comes to being sorted after use.
It means thousands of tonnes of plastic waste, historically sent to landfill or for incineration, can be recycled instead.
The firm's system combines various pigments to achieve a black colour, while maintaining the infrared reflectance of the underlying polymer.
Using undetectable black and coloured product has often come at an environmental cost.
According to the European Recyclers' Association, 870,000 tonnes of polyester are landfilled in Europe each year – much of which is black and coloured.
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Colour Tone’s detectable colouring solutions provide an opportunity for retailers and brand owners to increase recycling rates, ensure plastic reuse and reduce landfill.
The firm's general manager Simon Atterby has been leading its collaboration with the Accelerated Growth Programme (AGP), the Welsh Government’s business development scheme which looks to provide help and support for firms wanting to expand.
The work with AGP has helped Colour Tone – which employs 50 people and has a turnover of around £5.5m - to develop its latest technology as well as identifying new export markets
Mr Atterby said the near infrared detectable product range, which has been in development since 2010, has major potential.
He said: “This is a product that provides a solution to a global problem and has the potential to provide huge sustainability benefits on a global scale; something which we are very proud of.
"We applaud the brand owners and retailers who have chosen to make the switch to this new technology already and encourage those considering making the switch to do so.
“Unfortunately, however ,consumers are receiving mixed and confusing messages which may lead them to believe black plastic is not recyclable, this is incorrect and when coloured with an infrared detectable colour pack it can be detected and recycled.
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“The consumer has started to think that black plastic is not recyclable, but that is not true – in fact colouring black can often be very sustainable in that it provides a mechanism for reusing recycled plastics into the product and can be recycled at end-of-life.”
Mr Atterby said that black plastic has many benefits – one of the main ones being that packaging manufacturers can use recycled content in their products, improving their green credentials and the sustainability.
It means Colour Tone’s product can both use recycled material while also building end-of-life recylability into the product design.
Other colours containing infra red absorbing pigments are also affected, particularly where they contain carbon black pigment, for instance greys.
David Notley of the Excelerator Consortium, which delivers the AGP said: “Colour Tone Masterbatch is a company at the cutting edge of plastics development. The work put in has the potential to really help the fight against plastic waste.
“It is another example of a Welsh business at the forefront of its sector. Working with the AGP has helped Colour Tone’s expansion plans and developed its growth into new markets.
“Colour Tone Mastebatch has an exciting future ahead and we hope to continue to help to encourage it to grow."