Bioplastics
in South Africa
2016
JUNE 2016
Report compiled by Jacques Lightfoot – PlasticsǀSA
TABLE OF CONTENT
1)
PlasticsSA: Bioplastics in South Africa .............................................................................. 3
Defining Bioplastics.................................................................................................... 3-6
2)
PlasticsSA Position Paper .............................................................................................. 7-9
3)
PlasticsSA Bioplastics How-to-Guide............................................................................... 10
4)
PET Bottle Value Chain In SA ......................................................................................... 11
5)
Current PET Manufacturing Value Chain In SA ............................................................... 11
6)
Producing a 500ml PET Bottle in SA .......................................................................... 12-17
7)
Current Bio-PET Valpre PlantBottle in SA .................................................................. 18-22
8)
Future 100% Bio-PET Plant Bottle in SA .................................................................... 23-24
9)
Introduction to PET Recycling .................................................................................... 25-28
10)
Certification of Bioplastics........................................................................................... 29-34
11)
Terms of Reference ......................................................................................................... 35
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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PLASTICSǀSA: BIOPLASTICS IN SOUTH AFRICA
Bioplastics form part of the bio-economy concept, which focuses on sustainable production and conversion
of biomass into a broad range of products. Although Bioplastics is a relatively new field within the South
African Plastics sector, it is driving the evolution of the plastics industry and represents a crucial pillar of the
bio-economy.
Advancements in bioplastics research and innovation, will allow South Africa to improve the management
of its renewable biological resources and to open new and diversified markets in food and bio-based
products. Establishing this new sector holds great potential to create economic growth and sustainable jobs,
reduce fossil fuel dependence, and improve the economic and environmental sustainability of primary
production and processing industries.
Defining Bioplastics
1. What differentiates bioplastics from conventional plastics?
The term bioplastics encompasses a whole family of materials which differ from conventional plastics insofar
as that they are bio-based, biodegradable, or both.
It is important to understand that bio-based polymers are not always biodegradable and biodegradable
polymers are not always bio-based.
Bioplastic Pellets
2. Bio-based Plastics
Bio-based means that the material or product is derived from biomass (plants). Biomass used for bioplastics
stems from e.g. corn, sugarcane, or cellulose.
Bio-based plastics made from renewable resources can offer similar, additional or even better functionality
depending on its composition. The use of renewable resources as feedstock in the production of bio-based
materials is seen as a way of reducing the dependency on fossil oil.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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3. Bio-degradable
The term biodegradable refers to a chemical process during which micro-organisms that are available in the
environment, convert materials into natural substances such as water, carbon dioxide and biomass (artificial
additives are not needed!).
The process of biodegradation depends on the surrounding environmental conditions (e.g. location or
temperature), on the material itself, and on the application. Biodegradability is an inherent property of
certain bioplastic materials that can benefit specific applications (e.g. bio-waste bags or service ware).
4. Compostable
A compostable plastic is biodegradable in a composting environment, yielding H₂O, CO₂, biomass and
inorganic compounds. The biodegradation during composting should be at a rate similar to other known
compostable materials, and should not leave visual or toxic residue.
In order for a plastic to be labelled compostable, it must meet scientific standards, such as the ASTM
specification D6400-127:
 Disintegration: No more than 10 percent of the original dry weight of a product must remain after 84
days in a controlled composting test.
 Biodegradation: 90 percent of the organic carbon in the test materials must be converted to carbon
dioxide within 180 days.
 Non-toxic to plants: The product must have less than 50 percent of the maximum allowable
concentrations of certain heavy metals regulated by biosolids (U.S. EPA503). Compost must also be
able to support germination of two different plant species at a rate of at least 90 percent of that in a
“control” sample.
5. Bioplastic Materials
Bioplastics are not a single kind of polymer but rather a family of materials that can vary considerably from
one another. There are three groups in the bioplastics family, each with its own individual characteristics:

Bio-based or partially bio-based, non-biodegradable plastics such as bio-based PE, PP, or PET (so-called
drop-ins) and bio-based technical performance polymers such as PTT (Poly Trimethylene Terephthalate)
or TPC-ET (Thermoplastic Polyester Elastomer).
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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
Plastics that are both bio-based and biodegradable, such as PLA (Poly Lactic Acid) and PHA (Poly
Hydroxyalkanoates) or PBS (Poly Butylene Succinate).

Plastics that are based on fossil resources and are biodegradable, such as PBAT (Polybutyrate Adipate
Terephthalate).
6. Bio-based, biodegradable, non- biodegradable and compostable plastics
Diagram: Courtesy of European Bioplastics
‘Bio-based’ does not equal ‘biodegradable’. The property of biodegradation does not depend on the
resource basis of a material, but is rather linked to its chemical structure. In other words, 100 percent biobased plastics may be non-biodegradable, and 100 percent fossil based plastics can biodegrade.
Bio-based plastics include:
1. Bio-based, non-biodegradable plastics
Materials: Bio-based Polyethylene (Bio-PE), bio-based polyethylene terephthalate (Bio-PET), bio-based
Polyamides (Bio-PA), some bio-based Polyesters (PTT, PEF), starch-Polyolefin blends, and
other materials.
Uses:
In packaging as well as in durable applications such as vehicles, buildings, household
appliances, interior design, lifestyle goods, and electronics.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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2. Bio-based, biodegradable and compostable plastics
Materials: Thermoplastic starch, Polylactic Acid (PLA), Polyhydroxyalkanoates (PHA) and others.
Uses:
Short-lived applications such as in agriculture, catering products, packaging, or thin bags.
Suitable for organic recycling, especially industrial composting.
Standards: In the EU, compostable products are certified under EN 13432 and EN 14995.
7. Oxo-plastics DO NOT biodegrade
Oxo-plastics are not bioplastics. A careful distinction is needed between biodegradable plastics and plastics
that are advertised as “oxo-degradable” or “oxo-biodegradable”.
The latter products are made of traditional plastics supplemented with specific additives. They do not fit the
definition of a ‘bioplastic’, so in order to minimise confusion of terms in the market place, the European
Bioplastics have recommended that the specific terms ‘compostable’ or ‘oxo-fragmentation’ (plastic dust)
be used wherever possible.
8. What are the benefits of Bioplastics
Bioplastics are driving the evolution of plastics. There are two major advantages of bio-based plastic products
compared to their conventional versions:
 They save fossil resources by using biomass which regenerates (annually) and providing the unique
potential of carbon neutrality.
 Furthermore, biodegradability is an add-on property of certain types of bioplastics. It offers additional
means of recovery at the end of a product’s life.
9. Markets for Bioplastics
Bioplastics can be used in a number of markets – from packaging, catering products, consumer electronics,
automotive, agriculture/horticulture, toys and textiles to name a few.
Images: Shutterstock
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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PLASTICSǀSA’S POSITION PAPER: VIEW ON DEGRADABLE,
BIODEGRADABLE AND OXO-BIODEGRADABLE PLASTICS
(16 October 2013)
As the use and publicity of degradable plastics increases, so does the confusion surrounding the
environmental claims put forward. The general perception is that degradable plastics will dissolve and
disappear over time versus conventional plastics that will be around forever. It is not that simple.
PlasticsǀSA has created this position paper with the intention of better informing the public, media and
packaging decision makers.
As a result of insufficient or incorrect information, consumers often base their decisions on foreign, poorly
researched or emotional articles. Each country needs to find its own unique solutions to litter, municipal
solid waste and poor human behaviour.
Position

PlasticsǀSA welcomes and supports any innovations that enable plastic products to meet the required
high quality performance standards.

PlasticsǀSA recommends that any product environmental impact should be measured against
comprehensive Life Cycle Assessments together with costs evaluations. As such, it is not correct to
assume that oxo-biodegradable or bio-based plastics have by definition a lower environmental impact.

It is crucial that any environmental claims are backed by sound science and standards. All environmental
claims such as biodegradability, compostability or the bio-based content are in compliance with
appropriate standards such as ISO 14021.

It must be emphasised that market requirements will remain a determining factor in choosing the plastic
grade with the desired property profile. The choice is therefore directly related to the functionality and
not to the raw material base of the plastic which can be either fossil or bio-based.

Biodegradable plastics are not a solution for littering. Plastics recycling is an integral part of South Africa’s
economy. Over the past few years South Africa has recycled more than 100 000 tons of plastic bags,
wrapping and film every year.

PlasticsǀSA seeks to build confidence in the technical integrity of recycled material that is able to
demonstrate its ability to perform as a viable alternative to virgin plastics. If a proportion of recycled
plastic contains oxo-biodegradable material, it could change the characteristics of the material and may
lead to a failure of products as degradation occurs, resulting in the hindering of market acceptance which
will lead to reduced value of recycled material in South Africa.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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Influence on Environment
It is important to understand that bio-based plastics are not always biodegradable and that biodegradable
plastics are not always bio-based. It is possible to make biodegradable polymers from fossil raw materials. It
is essential to make this distinction in order to avoid confusion when addressing different societal and
environmental concerns of bioplastics. It is also essential that those who use the additives consider the
sustainability implications of these additives on the recyclability of plastics.
Definitions
Many stakeholders use the general term “bioplastics” to describe different concepts, often leading to
confusion. Biodegradability and compostability as material properties are regulated by international
standards.
We distinguish between the following:

Biodegradable plastics are degradable due to the action of micro-organisms and enzymes. The aerobic
or anaerobic decay of biodegradable plastics by micro-organisms is the conversion of the organic matter
into carbon dioxide (or methane); mineral salts and water under specific environmental conditions,
either through processes in nature or man-made (degradation in industrial composting plants, anaerobic
digestion plants, etc.).

Compostable plastics are degradable due to a biological process occurring during composting and are
converted into carbon dioxide, water, mineral salts and biomass. There are no toxic side effects like toxic
residue for water, soil, plants or living organisms. Note that not all biodegradable materials meet
compostable criteria. Materials which do not fulfil these criteria may still be biodegradable under specific
environmental conditions. To ensure that waste treatment facilities work properly, only plastic waste
which is compliant with the standards and requirements of the respective facility enters composting
streams.

Bio-based plastics are plastics derived entirely or partially from renewable resources, such as vegetable
fats and oils, corn or starch. Fossil-fuel plastics are derived from petroleum. The use of renewable
resources as feedstock in the production of bio-based materials is seen as a way of reducing the
dependency on oil. Bio-based plastics made from renewable resources can be used in a variety of
applications and complement currently used fossil based products. Bio-based plastics can offer similar,
additional or even better functionality depending on its composition.

Oxo-degradable plastics degrade when exposed to heat and/or light. The additives serve to initiate and
accelerate break-down of the plastic by a process known as ‘oxidative degradation’. Exposure to heat
and/or light causes the molecules to break apart so that the plastic weakens in strength, becomes brittle
and fragments into small pieces. The time taken for the plastic to start to degrade will depend on the
amount of additive in the plastic and the type of environmental conditions it is exposed to. Therefore, it
is not possible to accurately predict when the plastic will start to degrade.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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Conclusion
Plastic recycling is an integral part of South Africa’s economy.
Recycled plastic waste is used to make many new long-term plastic products such as bags, refuse bags,
agricultural- and building products such as water pipes, builder’s film, fencing and decking.
One of the challenges faced by the plastics recycling sector over the past decade has been that of building
confidence in recycled material and demonstrating its ability to perform as a viable alternative to virgin
plastics.
The real concern is the impact of a degradable additive once the plastic is recycled and used in second and
successive applications. A large quantity of recycled plastics goes into carpeting, geo-textiles, strapping,
plastic timber and pipe. The concern is what will happen when the polymer molecules break down during
the expected service life – failure and potentially expensive remediation.
A final concern about degradable, biodegradable and oxo-biodegradable packaging is that the product is
composed of non-renewable fossil fuel based inputs and there is little difference in regards to energy and
resource usage when compared to conventional disposable packaging. If biodegradable and oxobiodegradable packaging are meant to break down in a landfill environment, the products will not be
recovered through waste management and recycling initiatives, resulting in a loss of resources (the calorific
value of plastics) in the same way these resources are lost if they are not recycled.
Solutions to litter and irresponsible consumer behaviour should be sought and South Africans should be
encouraged to embrace the strong and viable recycling industry by designing plastic products and packaging
with recycling in mind. This will continue to provide jobs and keep our natural resources in circulation.
Plastics SA is committed to a policy of achieving zero plastic to landfill as determined by the Waste
Management Act. In line with this objective, Plastics SA therefore recommends that no Oxo-biodegradable
products be used as these would contaminate the recycling waste stream, thereby reducing the value and
recycling rates of plastic. If, however, further scientific evidence shows that there are other benefits to
the use of Oxo-biodegradable products, PlasticsǀSA will reconsider its position.
PlasticsǀSA represents the plastics industry of South Africa. Its members represent all sectors of the SA Plastics Industry including
polymer producers and importers, converters, machine suppliers and recyclers.
PlasticsǀSA operates from three centres: the Head Office in Midrand, Gauteng and the two regional centres located in Pinetown
KZN and in Cape Town. PlasticsǀSA provides industry training and drives the plastics industry Environmental initiative.
For more information visit: www.plasticsinfo.co.za
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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PLASTICSǀSA’S BIOPLASTICS HOW-2-GUIDE
PlasticsǀSA has developed a Bioplastics ‘How-2-Guide’ as part of their marketing and communication
strategy. The aim of the How-To-Guide is to inform the general public and industry on bioplastics.
Front Page
Back Page
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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PET BOTTLE VALUE CHAIN IN SOUTH AFRICA
What is PET?
PET stands for Polyethylene Terephthalate, a plastic resin and a form of polyester. Polyethylene
Terephthalate is a polymer that is formed by combining two monomers called modified ethylene glycol and
purified Terephthalic acid. PET is the plastic labelled with the #1 code on or near the bottom of bottles and
containers and is commonly use to package soft drinks, water, juice, peanut butter, salad dressings and oil,
cosmetics and household cleaners.
History of PET - Polyethylene terephthalate
1929 – 1931 The synthesis of polyesters was first explored intensively by Wallace Carothers whilst working
at DuPont.
1941
Polyester (PET) was first developed by British chemists, John Rex Winfield and James Dickson,
in the laboratory of a small English company.
1950’s
Polyester came into use as a fibre for cloths and textiles through developments by DuPont
and ICI (Terylene).
1960 – 1970 Polyesters were first used in film wrapping, sheet, coating and bottle applications.
1973
The first PET bottle was patented by Nataniel Wyeth
1977
The first PET bottle was recycled!
CURRENT PET MANUFACTURING VALUE CHAIN IN SOUTH AFRICA
For the purpose of this Biomaterials study, the 500ml Coca-Cola™ bottle has been chosen as an end-use
product. The entire PET market consumes roughly 250 000 tons of PET every year in South Africa.
Diagram: By J Lightfoot (PlasticsǀSA)
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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PRODUCING A 500ML PET BOTTLE IN SOUTH AFRICA
Step 1: Manufacturing of PET Resin
Traditionally, PET resin is manufactured from natural resources; including crude oil and natural gas. Oil is
used to produce the PTA (Purified Terephthalic Acid) and natural gas is used to produce the MEG (Mono
Ethylene Glycol) portion of the resin in a ratio of 70% and 30% respectively.
There is one major PET resin manufacturer in South Africa, Hosaf Fibres. Hosaf was launched in 2001 and is
a successor company to the polyester operation started by Hoechst. Production of virgin resin and polymers
is done in Jacobs, south of Durban (KZN). In addition, Hosaf operates a fibre production plant in Cape Town
and a PET recycling plant in Johannesburg.
There are two key stages in PET manufacture: production of polymer chip in an amorphous state followed
by solid state poly-condensation to raise its Intrinsic Viscosity (IV), thereby achieving the strength and
resilience demanded in bottling applications.
The Jacobs operation comprises of a continuous process (CP) plant – the only one in Africa – and two batch
plants. The Jacobs CP plant was commissioned following Durban’s first full environmental impact study, an
indication of the industry’s early adoption of sustainable environmental practice and willingness to engage
local communities. Its production processes carry Federal Drug Administration (FDA) approval, a global
quality benchmark in this field. Production quality also conforms to all relevant European Union directives
as Hosaf complements production for South African customers with exports to overseas markets, primarily
in Western Europe.
PET Pricing:
R 18123.00 per tonne (May 2016)
PET Grades
Hosaf will add certain additives (Modify material properties) to the PET resin to produce certain grades of
PET. These grades of PET will be designed to meet certain standards required by their customers. For
example; The Coca-Cola Company would require a bottle-grade PET plastic resin for their process, as this
grade is designed to work with the Injection Moulding and Blow Moulding processes.
Hosaf has four PET grades;
1. The standard Cazeden T86 with IV (Intrinsic Viscosity) 0.83.
2. Variant T96 with IV 0.86 – This grade was designed to assist plastic converters using recycled PET as
recycled materials resin currently available in SA has a lower IV of around 0.75.
3. Polyclear™ 1101, a fast re-heat made under licence from Invista (This is the principal resin from CSD Carbonated Soft Drink).
4. The fourth grade is the Cazeden BioPET manufactured for Coca-Cola where the MEG portion is derived
from plants and not oil or gas.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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Step 2: Plastics Manufacturing of Preforms
The PET resin will be transported to a Plastics Converter (a plastics manufacturing company), that will convert
the raw material, or resin into a plastic product.
PET converters produce four principal types of product : pre-forms (essentially, a bottle in embryo), singlestage bottles (pellet turned into a finished bottle in one process), two-stage bottles (pellet to pre-form which
is then blown into a finished bottle) and multi-layer bottles (still relatively uncommon in South Africa, but
essentially a bottle that makes use of different types of plastic). Converters may also make the closures
(bottle tops) that ensure the integrity of a bottle’s contents. The conversion process involves either stretchblow moulding or injection-moulding.
In the case of a PET bottle, first a preform needs to be produced. Preforms are made from the injection
moulding plastics manufacturing process. The 550 Ton (clamping force) Injection Moulding machine costs
around R4 million and the high tech (hot runner) 144 cavity mould costs around R1.5 million.
Preforms are produced by injecting hot melted plastic into a mould cavity (certain shape and dimensions).
The preform is then cooled by water flowing through the mould, and after a certain period the mould is
opened and the preforms are ejected from the mould. Preforms are manufactured using a multi cavity
mould, ranging from 32-144 preforms that are produced during a single shot of the machine cycle. Random
sample testing is conducted on the preforms, whereby preforms are tested for quality, dimensional stability,
clarity and surface finish.
32 Cavity Preform Mould
144 Cavity Preform Mould
Photos: Courtesy of J Lightfoot (Chinaplas 2015)
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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There are several plastics manufacturing companies that produce preforms for the South African market.
Preforms come in many different sizes and colours, depending on the final product that is required.
Images: Shutterstock
Preforms are produced and stored in bulk containers, before being transported to a bottling plant, where
the bottles will be heated and blown into the desired bottle shape.
The preforms that will produce the 500ml Coca-Cola ™ bottle are currently manufactured by Mpact Plastic
Converters. There are a total of 38 plastic converters that manufacture preforms for the Coca-Cola Company,
as there are many different sized preforms within the company’s product range.
Step 3: Plastics Manufacturing of Bottles
In South Africa, ABI Bottling (Amalgamated Beverages Industries) is the leading soft drink business in the
international SABMiller plc group of companies and remains one of the largest producers and distributors of
the Coca-Cola Company brands in the southern hemisphere.
ABI accounts for approximately 85% of Coca-Cola's sales in South Africa and has five state-of-the art
manufacturing plants (Midrand, Pretoria, Devland, Phoenix and Premier Place) that distribute more than 300
million unit cases per year.
Bottlers use preforms and blow them into the desired bottle shape, before filling them with product from
the manufacturer.
Photos: Courtesy of J Lightfoot (Chinaplas 2015)
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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Blow moulding Process
Preforms are placed in hoppers and fed into the Blow moulding machine. The preforms are heated below
the bottle neck with infra-red lights to a desired temperature, normally at 200°C. The preforms are then
moved along the conveyor to the blowing station, where two mould halves enclose the preform.
Compressed air is forced info the mould, where the heated preform changes it shape and conforms to the
shape of the mould. The compressed air also cools down the new bottle. The two mould halves open and
the new plastic bottle moves along the conveyor to the next station, where the bottle will be rinsed and
filled with the desired product and sealed with a closure (bottle cap) made from High-Density Polyethylene.
Diagram: Complete Bottle manufacturing process
The bottle is then transported along a conveyor to the labelling station, where a polypropylene label is
wrapped around the bottle. Both the closure and label are made from the Polyolefin type of plastics, so that
when the bottle is recycled, the PET and Polyolefin material can be separated during the washing cycle of
the process.
Once again, random sampling is conducted to check quality and shape of the PET bottle.
Packaging at Retail store
Products are sent to retail stores and shelves are stocked with the product.
Image: Shutterstock
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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Extended Producer Responsibility (EPR)
Extended Producer Responsibility (EPR) is a necessary step for various industries to become more
responsible corporate citizens. As a principle of product policy, EPR was first introduced in the early 90s in
an attempt to address the lifecycle issues of products with a specific focus on what happens to them at the
end of their life. In essence, EPR is a policy approach under which producers accept significant responsibility
(financial and or physical) for the treatment or disposal of post-consumer products.
A target oriented approach is used for different EPR programmes, instead of a more traditionally controlled
regulation. This is achieved by extending the responsibility of producers beyond their factory gates. In some
programmes economic incentives are set in order to achieve set targets for collecting, re-using and recycling
post consumer products.
From a waste management perspective, an EPR programme helps to reduce the financial and physical
burdens which are placed upon waste management authorities. An improved product design coupled with
infrastructure development for post-consumer collection and recovery can ideally facilitate closing a part of
the material loops.
The PETCO model is built on the simple principle of establishing an industry-driven and industry-financed
environmental solution for PET and has proven to be sustainable. By taking responsibility for post-consumer
PET recycling, PETCO imposes accountability over the entire life cycle of PET products and packaging which
means that manufacturers, importers and/or sellers of PET packaging are financially and physically
responsible for such packaging material after its useful life.
A recycled PET polymer is used in production of various items such as polyester carpet fibre, T-shirt fabrics,
underwear and sweaters, athletic shoes, luggage, upholstery, fibrefill for sleeping bags and winter coats;
industrial strapping, sheet and film; automotive parts and new PET containers for both food and non-food
products.
PETCO’s History
PETCO is the trading name of the PET Recycling Company NPC, and represents the South African PET plastic
industry’s joint effort to self-regulate post-consumer polyethylene terephthalate (PET) recycling and end of
life solutions.
The Company was established in 2004 – formalising the model envisioned by the PET Committee initially set
up in late 1998 by concerned industry in the PET sector - brand owners, resin manufacturers, converters and
bottlers, with Coca-Cola playing a leadership role.
PETCO’s unique model is built on the simple principle of an industry driven and financed environmental
solution for post-consumer PET plastic. To achieve this everyone involved, from the raw material producers,
the converters, brand owners, retailers, consumers and recyclers are playing their part in the solution, with
PETCO fulfilling the PET industry’s role of Extended Producer Responsibility (EPR).
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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PETCO is financed by a voluntary recycling levy paid (R385/Ton of PET) by converters on PET resin purchased.
PETCO also receives grants from brand owners, resin producers and retailers. Support for PET recycling
efforts ensures an ongoing monetary value for post-consumer PET. This sustains collection interest and
reduces the volume of post-consumer PET in the waste stream.
By taking responsibility for post-consumer PET recycling, PETCO imposes accountability over the entire life
cycle of PET products and packaging. This means that companies which manufacture, import and/or sell PET
products and packaging are financially and physically responsible for such products after their useful life.
Ongoing consumer and public education and awareness activities promote environmental responsibility and
encourage PET recycling.
Much has been achieved in terms of PET Recycling since 2004. After a decade of notable achievements, the
PET industry can look back and reflect with some pride on how its commitment to PETCO has illustrated that
voluntary extended producer responsibility (EPR) initiatives are successful when they have the support and
commitment of an entire industry value chain.
What began with one small project and a vision of voluntary financial support and commitment from the
industry has resulted in the development of national networks for PET collection, sorting and recycling, and
placed South Africa on a par, and indeed ahead of, many other countries.
Over the decade, the local PET recycling industry has expanded its collection network and increased recycling
tonnages year-on-year. PETCO has invested R235 million in support of contracted recyclers, ensured that a
total of R 1.2 billion was paid to collectors by PET recyclers, facilitated the creation of R 2.9 billion worth of
new products containing rPET, and becoming the catalyst for R900 million worth of investment in
infrastructure development.
In 2015, PETCO achieved a recycling rate of 52% and has closed the loop for bottle-to-bottle carbonated soft
drink (CSD) grade bottles.
Diagram: Courtesy of PETCO
PET copy provided by PETCO: www.petco.co.za
PETCO 1isPET You Tube, Facebook, Instagram, Twitter
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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CURRENT BIO-PET VALPRÉ PLANTBOTTLE IN SA
Diagram: By J Lightfoot (PlasticsǀSA)
Photos: Courtesy of J Lightfoot (Valpré Spring Water, Heidelberg 2016)
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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Bio-PET - Resin
So what is the difference between Bio-PET and traditional PET? Bio-PET starts its process by first planting a
crop, with sugar being the material/product of choice. As mentioned in a previous section, Polyethylene
Terephthalate (PET) is made out of 32.2 wt% Mono Ethylene Glycol (MEG) and 67.8 wt% Purified
Terephthalic acid (PTA), combined in an esterification reactor and converted to polymer in a polycondensation reactor.
To reach 30% bio content, the Coca-Cola Company buys bio ethanol from Brazil (South America). The Bio
Ethanol gets shipped to India and it is converted into bio MEG, which is then used to manufacture the 30%
bio content PET bottle.
How Bio Content PET is made
Brazilian Bio-ethanol is derived from fermenting sugar cane juice. It’s available on the open market through
a number of large distributors. Coke also uses bio ethanol from India, derived from molasses, a by-product
of sugar refining. Bio ethanol goes to India Glycols Ltd. in Noida, India (www.indiaglycols.com), which has
been making bio MEG since 1989 for pharmaceuticals and other markets and is the world’s only large
commercial producer of bio MEG.
India Glycols converts bio ethanol into bio ethylene oxide and then into bio MEG. Its capacity grew steadily
from 20,000 tons/year initially to 60,000 tons/year by 2002, according to a published company history. In
2005 India Glycols nearly doubled its combined Bio Ethylene Oxide and bio MEG capacity to 100,000
tons/year, then doubled it again to 200,000 tons/year in 2008, ahead of Coke’s ‘PlantBottle™’ launch.
Plastics Manufacturing Process of 30% Bio PET bottle
The Process of producing a 30% bio-PET bottle will be identical to the process of a convention oil/gas
derived PET bottle.
Step 1: Bio-MEG added to oil derived PTA (purified Terephthalic Acid)
This process is completed by Hosaf in South Africa. Currently the BioPET is 10% more expensive than the oil
derived PET.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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Step 2: Plastics Converter - Preforms
Boxmore Packaging injection moulds the preforms for Valpré. The latest preforms conform to the new
shorter neck-finish global standard, the PCO 1881 ISBT (3,8g/17mm), and is capped with the two-piece
‘Super Shorty’ closure for soft-drink PET bottles, supplied by Nampak Closures. It weighs 2,4g versus 3,2g for
the previous closure.
Background: Boxmore Packaging:
Boxmore Packaging is one of the largest converters of PET resin in Southern Africa and supplies pre-forms to
the region’s beverage industry and to its clients on the African continent.
They currently produce more than 1.6 billion pre-forms annually, in 50 unique pre-form designs. Their
diverse customer base requires that they have to develop pre-forms in various neck finishes and colours,
and although they have a range of standard colours, their pre-forms can be produced in a variety of colours;
from tints to opaque and can be matched to specific colours.
Step 3: Blow Moulding and filling
The giant packaging hall comprises separated areas for high-care blowing and filling, downstream labelling
and end-of-line packaging.
The Krones Contiform 24 PET blow moulder and filler are housed in an ISO Class 7 clean room. The preforms
are transported from a hopper to the blow moulder via a Krones Inspection system that ejects any damaged
units, and are then air rinsed prior to entering the 24-cavity blow moulder. Using lightweight moulds which
equate to far less machine stress, it runs at the same speed as the filler – i.e. 40 000 bottles/hour for 500ml
units.
The Krones Contiform Blow Moulding machine costs around R11 million, with an additional R23,000.00 per
mould for the 500ml bottle design. This means an additional investment of R552,000.00.
The preforms are handled ‘right side up’ through the heating tunnel (the preform body is heated to 200°C
by infrared heater) and into the blowing carousel which means no additional parts are required to invert
them into position. Heated high-pressure air used in the blowing process is recycled back into the system.
The PET filler is directly blocked to the blow moulder which eliminates any airveyors and the necessity to
rinse the bottle before filling – thus ensuring additional energy and rinse media savings.
The volumetric PET filler is especially designed to handle still and sparkling water – for example, non-contact
filling with still water as a precaution for safety/hygiene purposes. Specially adapted flow meters control the
filling volume due to the low conductivity of the product. The bottles are handled by the neck and therefore
no change parts for different sized bottle are necessary.
The filled bottles are transported to the downstream labelling and end-of-line packaging.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 20 of 35
Photo: Courtesy of J Lightfoot (Valpré Spring Water, Heidelberg 2016)
Photo: Courtesy of J Lightfoot (Valpré Spring Water, Heidelberg 2016)
Step 4: Retailers
The PlantBottle™ has become very successful and has shown that the Coca-Cola Company is committed to
looking after South Africa’s natural resources and to becoming more environmentally conscious. Consumers
are also more willing to pay a ‘green’ premium for a quality product.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 21 of 35
Step 5: Recycling (EPR – Extended Producer Responsibility)
The Bio PET bottles are collected with conventional oil-derived PET bottles and make their way to several
PET recyclers in South Africa. All of the PET bottles are washed, flaked, dried and re-melted into pellets, to
be sold to other plastic converters who will either produce polyester fibre, other PET bottles or sheeting. The
recycling process is a closed loop system in South Africa and currently 52% of all PET bottles in South Africa
are recycled. Through the great efforts of PETCO, this number has been increasing year on year.
Collection
Flaking
Pelletising
Photos: Courtesy of PETCO
Image: Courtesy of PETCO
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 22 of 35
FUTURE 100% BIO-PET PLANT BOTTLE IN SA - PLANTBOTTLE™ 2.0
Diagram: By J Lightfoot (PlasticsǀSA)
Diagram: By J Lightfoot (PlasticsǀSA)
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 23 of 35
100% Bio PET bottle
The Coca-Cola Company launched the world’s first PET plastic bottle made entirely from plant materials at
the World Expo in Milan during June 2015.
Virent and bio-PET bottle manufacturer FENC (Far Eastern New Century) based in Taiwan, successfully
demonstrated production of a 100% bio-based PET bottle as part of Coca-Cola’s PlantBottle™ program in
2014.
The bio-based Paraxylene (PX) is supplied by Virent made using sugar as its starting material and produced
via its patented Bio-Forming process. FENC then converts the BioForm PX to bio-PTA, and subsequently to
100% bio-based PET resin.
PlantBottle™ 2.0 packaging is The Coca-Cola Company’s vision to develop a more responsible plant-based
alternative to packaging traditionally made from fossil fuels and other non-renewable materials.
PlantBottle™ packaging uses patented technology that converts natural sugars found in plants into the
ingredients for making PET plastic bottles. The packaging looks, functions and recycles like traditional PET
but has a lighter footprint on the planet and its scarce resources. Coca-Cola currently has collaborations
with Virent, Gevo and Avantium for the bio-based PTA component (or PEF in the case with Avantium) for
PlantBottle™.
The Coca-Cola Company reportedly plans to continue investment in its award-winning PlantBottle™
packaging. Longer term, the challenge is to lower or even cut the premium costs for bio-based PET, and in
order to do this, investments for higher production volume for bio-MEG (and soon for bio-PX/bio-PTA or PEF
– Poly Ethylene Furanoate) will be required. But is there a strong enough demand pull for bio-PET from
brand owners/consumers in order to justify these investments?
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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INTRODUCTION TO PET RECYCLING
Polyethylene Terephthalate (PET), is currently recycled into rPET (Recycled-PET) which can be used to make
many new products, including polyester staple fibre/filament used for apparel (clothing), home textiles
(duvets, pillows, carpeting), automotive parts (carpets, sound insulation, boot linings, seat covers) and
industrial end-use items (geotextiles and roof insulation).
End-use market development
If there is not an end-use market for recycled PET (rPET), then there would be no point in collecting the PET
bottles in the first place. This is why viable end-use markets are so important to any recycling endeavour.
Recycled PET (rPET) is used for numerous applications:

More and more manufacturers are coming up with new ways to use post-consumer PET plastic. From
park benches to roof insulation, there are recycled plastics all around us.

Carpet companies use recycled resin to make polyester carpets. PET is spun into fibre filling for pillows
and quilts. Fibre is also used to make clothing, jackets and polar fleeces. PET bottles may even reappear
in the form of non-woven automotive carpets. The recycled material can also be rolled into clear sheets
or ribbon (for VCR and audio-cassettes).

Spunbond is used to create geotextiles, a material with applications in roof insulation or as a means of
combating soil erosion. Pellets are turned into engineering plastics, pumps, gears and chemical-resistant
components.

Industrial applications of recycled PET include manufacturing strapping tapes, magnetic tapes on smart
cards, X-ray film, cigarette filters and tennis ball felt. Often, the recycled material is simply returned to
bottle manufacturers for re-use.

In South Africa, bottle-2-bottle recycling is now a reality, i.e. making new bottles out of a significant
percentage of old bottles.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 25 of 35
Bottle-to-fibre
Globally, the most common end use for recycled PET is the polyester staple fibre market. This is often used
to make apparel, carpeting, pillows, duvets, insulation, car liners and geotextiles, with the latter being used
to line dams, roads and landfills.
Products: Duvets
Products: Pillows
Product: Roof Insulation
Photos: Courtesy of PETCO
Bottle-to-bottle
A growing end-use market is that of recycling back into packaging. This does entail more stringent health
and quality requirements than the fibre sector - and therefore not all bottles that are collected are suitable
for this end use. In particular rPET is an input material for non-food grade packaging for personal, homecare,
pharmaceutical and other uses. Since 2009 rPET has been blended with virgin PET in various ratios for use in
packaging for sandwich containers, trays, tubs and non-carbonated beverages.
Mpact invested R350 million in a new state-of-the-art PET recycling plant in Wadeville during 2015. The plant
will be fully operational at the end of 2016 and will process about 29 000 tons of PET plastic bottles a year,
generating 21 000 tons of new raw material. Collecting and processing 29 000 tons of PET bottles amounts
to a saving of about 180 000 cubic metres of landfill space each year - the equivalent of 75 Olympic-size
swimming pools. Mpact anticipates that about 1 000 jobs will be created directly and indirectly to operate
the new plant.
Bottle
to
Bottle
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 26 of 35
Recycling - Sorting and Processing (Content and photos, courtesy of PETCO)
The commissioning of a recycling plant entails substantial capital investment while the economics of
sustainable recycling require high collection volumes in order to contain costs through economies of scale.
However, the process – the PET Flow – is easy to understand and can be represented in a simple schematic:
Collection: Discarded PET bottles are purchased
Sorting: At the recycler the collected bottles are
from buy-back centres, collectors and municipal
drop-off centres, baled and delivered to the
recycling plant.
sorted according to colour and polymer, delabelled (where possible) and the caps and rings are
removed, which are generally manufactured from
Polypropylene for which there is a demand in South
Africa, so they get recycled too.
Washing: The bottles are washed to remove any
Shredding: The bottles flow from the washing
residual surface contamination as well as any
incompatible polymers that float in water through
a float/sink process. PET is heavier than water and
will sink; any other residual material floats to the
top of the tank and is separated out. In the PET
washing process, caps or labels manufactured from
polypropylene (PP) or high-density polyethylene
(HDPE) will float and can be easily removed.
machine into a granulator where they are shredded
and
reduced
to
flakes
before
being
screened. Flakes are dried and stored in silos
before being conveyed to a cutter-compactor and
extruder creating spaghetti like threads (shown
above).
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 27 of 35
Packing: After cooling and drying, the pellets are
Finished product: Small clear PET pellets, called
stored in jumbo bags until required as a raw
material ready to be used in the manufacture of
new products.
Recycled PET or rPET, are sold to end markets. As
with virgin PET, recycled PET (rPET) can be used to
make many new products, including polyester
staple fibre or filament used for apparel (clothing),
home textiles (duvets, pillows, carpeting),
automotive parts (carpets, sound insulation, boot
linings, seat covers) and industrial end-use items
(geotextiles and roof insulation), strapping, fruit
carton corner pieces and new PET packaging and
bottles for both food and non-food products,
closing the loop and creating a circular economy.
One that is restorative and regenerative by design.
It is generally blended in a ratio of virgin to
recycled, depending on the application required.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 28 of 35
CERTIFICATION OF BIOPLASTICS
As bioplastics are not readily distinguishable from regular plastics, it is necessary to provide a mechanism
ensuring their quality and labelling. This is done through a standardization and certification system.
Standards
Throughout the evolution of plastics, there have been different claims relating to their environmental
effects. Many of these claims, however, are not based on anything as credible as the results of certified
laboratories. To provide generally applicable, science based norms, standardization organizations worked
with experts from different fields of study to create standards for the field of bioplastics. Standards are a set
of rules that a product must comply with before it can obtain a certain label. The most important
standardization bodies in the world are:




ASTM
ISO
CEN
DIN
– American Society For Testing and Materials (USA)
– International Organization for Standardization (international)
– European Committee for Standardization (European Union)
– German Institute for Standardization
CEN (European Committee for Standardization) is an officially recognized standardization body within the
European Union. CEN standards are binding for EU countries, and the standards are transferred to individual
national standardization structures. This facilitates manufacturers’ entry to the European market once they
comply with the standard requirements. The first standard in the field of composting and biodegradation of
plastics was issued by DIN in 1997 (DIN V54900) and was later replaced by the European standard EN 13432.
Although each standardization organization has its own standards, they are mutually harmonized. European
and American certification organizations both recognize each other’s standards in the field of polymers,
plastics and compostable products. When a certificate is issued (e.g. based on EN 13432), the manufacturer
can easily obtain a certificate based on other standards. The above-mentioned standards are very similar to
one another, only differing in certain additional analyses that have to be performed. This way it is possible
to avoid duplication of analyses, which often entails additional costs and administrative burdens.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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The procedure for certifying bio-based materials, additives and products from renewable materials
Traditional plastics are made from fossil resources, which is not a sustainable solution. This is why the
development of plastics is turning towards using renewable resources. Using plastics made from renewable
resources reduces the negative environmental impact of the polymer industry as it reduces the consumption
of fossil-based resources. There are currently no regulations that would require plastics manufacturers to
disclose the presence of renewable resources within a product, however there is increased interest in the
industry and among consumer to create and buy environmentally friendly products.
Determination of bio-based content is based on the principle of measuring the activity of the 14C isotope.
Materials - both those based on fossil resources as well as those based on renewable resources - are mainly
composed of carbon that can be found in three isotopes in nature: 12C, 13C, and 14C. The 14C isotope is
unstable, decays slowly and is naturally present in all living organisms. The activity of 14C in living organisms
is very stable since is related to the concentration of 14C in the environment which is close to constant. When
the organism is deceased, it stops absorbing the 14C isotope from the environment. From that moment
onward the 14C concentration starts to decrease due to natural decay of the isotope. The half-life of 14C is
known to be 5 700 years. This is not noticeable in the range of a human life, but within 50,000 years the
content of 14C decreases to a level that cannot be measured. This means that the concentration of 14C in
fossil resources is negligible.
ASTM D6866 standard using the above principle is the basis for certifying materials, intermediate products,
additives and products based on renewable resources.
Certification
A certificate is an official document used to guarantee a specific characteristic. In the case of biodegradable
polymer materials, a certificate is an attestation that a product is degradable under the conditions specified
in the standard. In the case of materials made from renewable resources, the certificate proves that the
product contains a specific percentage of renewable content.
Certification is a process of obtaining a certificate; a process through which a third party issues a written
recognition that a product, process or service complies with specific requirements (regulations and
standards) under which a product, process or service is certified.
Certification organizations for bioplastics
The most important certification organizations in Europe are DIN CERTCO and Vinçotte. Both issue
certificates relating to bioplastics. DIN CERTCO issues certificates for products made from compostable
materials based on four standards that are very similar to one another. In addition to this certificate, Vinçotte
also offers certificates for plastics suitable for home composting and for plastics that are biodegradable in
soil and in water. Both organizations certify materials made of renewable resources based on the ASTM
D6866 standard. Certificates for biodegradable products are also issued by the Biodegradable Products
Institute (BPI) in the United States, the Japan BioPlastics Association in Japan as well as by other widely used
certification organizations.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 30 of 35
The process of obtaining a certificate is completely voluntary. The manufacturer contacts a certification
organization with an application containing information about the material and the product that they wish
to certify. The certification organization then provides a list of laboratories that have valid accreditation to
perform the testing methods required by the standard. The laboratories are attested by the certification
organization and an independent inspector, and receive accreditation in accordance with the EN ISO/IEC
17025 standard. In general, this means that the laboratory is qualified to perform the analyses for which it
is accredited. Once the analyses are completed the laboratory sends the testing report to the certification
organization, where experts review the results. Based on positive results, the certification organization issues
the manufacturer with compliance certificate for products and licenses them to use the certification labels.
Main certification organizations and their certificate labels for biodegradable plastics
COUNTRY
ORGANIZATION
BIO-BASED
CERTIFCATION LABEL
20 – 50 %
Germany
DIN CERTCO:
Additional
requirement:
volatile solids
> 50 % (mass)
50 – 85 %
> 85 %
20 – 40 %
40 – 60 %
Belgium
Vinçotte
60 – 80 %
> 80 %
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 31 of 35
Benefits of certification
There are various benefits to certification of products and materials. A certificate distinguishes bioplastics
from traditional plastics and proves that a material conforms to standard requirements. This is a clear
advantage over other products that do not have the certificate.
Products that bear certification logos give consumers a beyond-doubt proof of product/material properties.
The certification logo for compostable plastics enables simpler sorting of waste and correct handling and it
provides a guarantee about the product's quality.
Certification of compostable products
Compostability is a characteristic of packaging or plastics that enables them to decompose during the
composting process.
The EN 13432 standard requires:
a) Testing on ultimate biodegradability
b) Testing on compostability
c) Testing on plant eco-toxicity
d) Chemical characterization
These conditions are based on pass-fail values that uniquely distinguish between compostable and noncompostable packaging.
Biodegradability, eco toxicity, compostability and the content of heavy metals are the parameters that apply
to materials. Materials, intermediates and additives can obtain a registration—an attestation that they are
compliant with a standard. They are not entitled to the use of a certification label but advertisement is now
possible according to Trademark rules and Trademark usage guidelines. The certificate, certification number
and certification label can only be applied to a finished product, as an important factor for obtaining the
certificate is degradability, which is linked to the finished product and dependent on its physical form (e.g.
thickness). A certificate is assigned for a period of three years, during which verification testing is performed
on the product once per year. For material, intermediates and additives notification of registration is valid
for six years and undergoes a verification testing every second year.
Only final products shall be certified. Only final products are allowed to be labeled with the certification label
proving that a product is compostable but advertising is now possible also for materials, intermediates and
additives according to Trademark rules and Trademark usage guidelines.
Each product decomposes during the biological waste decomposition process in accordance with
specifically defined criteria, and should not have a negative effect on the composting process and the
quality of the resulting compost.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 32 of 35
COUNTRY
ORGANIZATION
STANDARDS
CERTIFICATES ATTESTING COMPOSTABILITY
CERTIFCATION LABEL
EN 13432, ASTM D6400,
ISO 17088,
Germany
DIN CERTCO
Germany
DIN CERTCO
EN 13432, ASTM D6400,
ISO 17088, EN 14995 +
if applicable AS 4736
Germany
DIN CERTCO
AS 5810
Belgium
Vinçotte
EN 13432, EN 14995
Belgium
Vinçotte
Special Vinçotte process
based on EN 13432 at
low temperatures
USA
Biodegradable products
Institute
ASTM D6400
CERTIFICATES ATTESTING OTHER BIODEGRADABILITY CHARACTRISTICS
Belgium
Belgium
Vinçotte
Vinçotte
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Special Vinçotte process
based on ISO 14851 or
ISO 14852
Special Vinçotte process
based on ISO 17556 or
ASTM D 5988 or ISO
11266
Page 33 of 35
Conclusion – Certification of Bioplastics
Certification of bioplastics is important as it gives choice to the consumer as well as provides information
about the correct handling of the product after it is used.
To prevent misleading statements and false information found in this area (“green-washing”), international
expert groups have developed standards to govern this field. Standards are sets of requirements that a
product should conform to. They also prescribe methods for analysis and threshold values for individual
parameters. Analyses are performed by laboratories nominated by certification organizations and their test
results are used by the certification bodies for assessment and to award certification labels that can be used
on final products. The certification logo is proof that a product conforms to specific requirements and is an
undeniable advantage compared to products without the logo.
Currently, in South Africa, there are no official standards, but the industry will adopt international standards
to conform on a global level.
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
Page 34 of 35
TERMS OF REFERENCE
1. PlasticsǀSA
-
www.plasticsinfo.co.za
2. PETCO
-
www.petco.co.za
3. SA Plastics Magazine
-
www.saplastics.co.za
4. Coca Cola South Africa
-
www.coca-cola.co.za/brands/valpre
5. ABI
-
www.abi.co.za
6. Packaging Mag
-
www.packagingmag.co.za
7. Business Wire
-
www.businesswire.com
8. European Bioplastics
-
www.european-bioplastics.org
9. Plastice
-
www.plastice.org
Report compiled by Jacques Lightfoot – PlasticsǀSA (June 2016)
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