Colouring PCR

With the world focused on reducing plastic waste; brand owners, packaging technicians and moulders are increasingly seeking sustainable options. PCR (Post Consumer Recycled) materials offer an obvious and instant solution by utilising waste packaging – reprocessing it into usable materials for re-moulding. The introduction of the UK Plastic Packaging Tax has accelerated this trend. Broadway has been colouring PCR material for many years. Not only are we able to formulate colours for customers looking to increase their use of PCR, but we’re able to give helpful advice too.

Brand owners understandably have high expectations for product aesthetics. Unfortunately using high levels of recycled plastic does pose limitations on which colours and effects can be successfully achieved. Sustainability improvements must be a priority for us all, we believe consumers will increasingly accept and even embrace aesthetic compromises if they understand the resulting environmental gains. We encourage our customers to consider using PCR, or increase the level of PCR in their products wherever possible – and we’re on hand to assist with our colouring expertise. We can show first hand how using recycled plastics will impact the appearance of the end product, by demonstrating this in our colour suite.

PCR material is typically tinted, so lighter, brighter and translucent colours are not always achievable. A good analogy would be washing your brush in a pot of water when using watercolour paints. As more colour is washed into the water, it becomes ‘muddy’. Once it loses its original clarity, it becomes impossible to make that water clear again or turn it into a bright colour. Using PCR is very similar in that the inherent tint of the base material will limit the effect the masterbatch can have when dosed into it. The other challenge is that recycled polymer will vary from batch to batch. So a colour which works with one batch of material, may need adjustments to the formula to give the same result when used with a different batch of PCR. If you’re considering increasing the use of PCR in your products, then please get in touch.

We’re also able to formulate masterbatches using PCR carrier resins. A significant proportion of every masterbatch is polymer, so for a brand to legitimately claim their product or packaging is “made from 100% recycled plastic”, their masterbatch must contain a PCR carrier resin (and no virgin plastic). The polymer within the masterbatch will typically form between 0.5% and and 2.5% of the finished moulding, although this can be higher.