Sorting at scale to advance quality in post-consumer recycled bulk food handles

Overview

This research explores whether sorting and isolating specific plastic components—such as packaging handles used in bulk food and beverage distribution—can produce higher-value recycled materials than the current practice of homogenizing mixed post-consumer recycled (PCR) plastics. Mixed resin streams combine polyolefins and polyamides with differing melt temperatures, viscosities, colors, and additives, creating materials that are difficult to compatibilize and often underperform virgin plastics. By curating single-resin streams from packaging handles, the project aims to short-circuit the traditional PCR supply chain and reintroduce these components into manufacturing with minimal reprocessing.

The work addresses open questions around the economics of alternative collection and redistribution models, the intrinsic value of PCR versus curated handle materials, and the resulting product attributes. Potential pathways include resupplying handles directly to original manufacturers or reforming them into new structures. The research is positioned within a broader value-engineering framework that seeks to align collection logistics, material properties, and end-use performance.

Technical specifications

Research approach:

• Collect post-consumer recycled resin and isolated plastic handles from warehouse distributors such as Costco and Sam's Club
• Conduct resin attribute assessments including density, crystallinity, melting point, mechanical behavior, and rheology at the University of Michigan
• Perform solvent extraction to quantify mass loss in PCR compared to refined single-resin materials
• Compare property profiles of typical homogenized PCR resins against curated handle materials, whether HDPE or PP
• Evaluate collection, redistribution, and reuse cost models to determine economic feasibility
• Share findings with manufacturers, retailers, materials recovery facilities, and handle suppliers to assess reuse capacity

Key materials under study:

• Polyolefin and polyamide packaging handles from bulk food and beverage containers
• Homogenized PCR resin benchmarks for comparative analysis
• Pure-stream HDPE and PP candidates for reprocessing or direct reuse

Technology readiness level

The project is at an early-stage research and concept-validation phase. The principal investigator has prior experience with soft materials characterization but has not yet conducted work specifically on post-consumer recycled plastics. A related educational proposal was submitted to the National Institute of Standards and Technology in July to develop teaching content on recycled plastics, which may complement this research. A more formal proposal and partnership agreements are pending before full experimental execution begins. Results from this study will inform the feasibility of establishing a dedicated collection and reuse infrastructure for plastic handles in the PCR supply chain.