Stronger together

Alan Schrob has spent 20 of his 30 years in the plastics industry encouraging circularity in a variety of roles, including business development, marketing and the rigid and performance films markets. His work has involved exploring innovation opportunities for downstream applications in plastics and plastics sustainability and improving plastic circularity.

“Our goal at Nova Chemicals was to reduce plastic waste through efficiency in packaging and production, maintain performance with lighter-weight materials and eliminate multilayer structures that could not be recycled,” he says. “This work led to the company’s commitment to a low-carbon, zero-plastic-waste future and my transition to postconsumer recycled [PCR] business development two years ago.”

Last year, Schrob was named director of mechanical recycling at Nova Chemicals and now helps create lower-emission, recycled products for converters and brand owners.

Schrob shares some of what he has learned about plastics circularity throughout his career.

Q: What lessons have you learned about the industry that have helped you throughout the years?

A: Creating a zero-waste economy is a complex problem that cannot be solved by any one company or any one step in the value chain. It requires collaboration between all areas of the value chain, even if building those relationships can feel challenging in the beginning.

The biggest takeaway from my career is that making progress on a global scale requires vulnerability. Sometimes, businesses must give up part of their competitive edge to solve larger problems.

At Nova Chemicals, we have had the most success when we prioritized cooperation and worked as a team with other partners to develop innovative solutions.

Q: What prompted Nova Chemicals’ decision to open a recycling facility in Connersville, Indiana? Why did you partner with Novolex Holdings LLC to operate it?

A: When we think about the plastics circular economy, it is about much more than just creating recyclable products and reducing plastic waste. We need to figure out how to incorporate recycled material back into plastic products. The Connersville facility will allow us to use our know-how, mechanical recycling technology and expertise to produce the highest-performing recycled polyethylene (PE) materials and help businesses throughout the value chain meet their objectives.

With Novolex as the operator, we can leverage the best practices they have developed through more than 15 years of producing and recycling plastic film.

Q: How have equipment suppliers helped advance plastics recycling?

A: The right recycling equipment is integral to producing quality PCR materials. In our Connersville mechanical recycling facility, Nova Chemicals will use state-of-the-art equipment that employs the most sophisticated processes available to produce consistent, high-performing rPE. We are seeing equipment manufacturers invest heavily in improving the performance of their recycling equipment to meet brand owner PCR objectives.

One such promising collaboration is the founding of Blueone Solutions, a joint venture between the Erema Group, a plastics recycling systems and extruder manufacturer, and Lindner Holding, an expert in waste management and washing facilities. The two companies plan to work together to optimize the recycling process and develop industry standards that can be replicated in facilities around the world.

Q: Where do you see upcoming opportunities for plastics recycling? What about challenges?

A: There is abundant opportunity for collaboration throughout the value chain, from resin producers and recyclers to packaging manufacturers to brand owners. We need to invest in recycling infrastructure to increase opportunities for recycling and then find uses for the PCR material.

In terms of challenges, recycled materials can be difficult to adapt into demanding product applications. Sorting and cleaning are required to produce feedstock of appropriate purity for downstream processors, and these processes require combined effort from recycling facilities and end users.

Q: How important is recycling to achieving Nova Chemicals’ ESG goals?

A: Recycling is an essential part of Nova Chemicals’ sustainability and decarbonization goals. By 2030, we aim to have 30 percent of our PE sales come from PCR content. We have already introduced our first portfolio of recycled PE (rPE) products, the Syndigo brand of resins, which will help our customers lower emissions and reduce waste. Achieving our targets will require a reliable supply of recycled PE, which is why we plan to invest $2-4 billion in recycling facilities and technologies.

Q: What role will chemical recycling play in Nova Chemicals’ future? What made a possible partnership with Plastic Energy attractive to you and are you exploring other opportunities in this area?

A: Both mechanical and chemical (or advanced) recycling techniques have their place on the path to plastics circularity. Nova Chemicals is exploring both options as we seek to incorporate PCR material into more types of packaging. In addition to the mechanical recycling facility in Connersville, we have entered into an agreement with advanced recycling company Plastic Energy to determine the feasibility of a pyrolysis-driven facility in Ontario.

Plastic Energy’s feedstock can be used to manufacture food-grade and high-performance PE, two applications that are very challenging for PCR content.

As we continue to discover new ways to extend the life of plastics, we will explore mechanical and advanced recycling projects and business models that strengthen the value chain and divert plastic from landfills.

Q: What misperceptions about plastics recycling do you wish you could debunk? What is the most effective way the industry can debunk these myths?

A: One of the biggest myths about plastics recycling is many people believe recycling is happening but the plastics that are collected are not being used. The best way the industry can debunk these myths is to be transparent about sustainability and recycling goals and share their progress freely so people can access accurate data about plastic production and recycling rates.

Plastics producers can also begin to take responsibility for recycling the products they produce, investing in facilities and infrastructure that will increase access to recycling. According to the American Chemistry Council, companies have invested in more than 90 mechanical and advanced recycling projects totaling $8 billion over the past six years, although more are still needed. Producers should work with trade organizations like the Association of Plastic Recyclers, whose membership has grown exponentially in the last decade, and who focus on creating meaningful change for the industry by supporting recycling legislation at the state and federal levels.

Q: How important are concerns about “greenwashing”—environmental claims that don’t hold up?

A: Greenwashing can be extremely detrimental to the companies who are making legitimate changes to their processes by creating recyclable packaging or using PCR material. When greenwashing is discovered from one source, it can undermine the public’s faith in the value of recycling. It is essential that trustworthy sources have access to and publish accurate, science-based data about the plastics industry.

Q: What advice can you offer to younger plastics recyclers entering the market?

A: In order for us to be successful in our zero-plastic-waste goals, the next generation of plastics recyclers will need a high degree of creativity. Innovative thinking and a willingness to take risks on promising opportunities will help you succeed. You have the opportunity to make a real difference in plastics circularity. Learn everything you can about the technical side of plastics manufacturing so you can work with customers to incorporate PCR materials into future applications.

It’s a big challenge, but we can build a more sustainable economy if we work together, share knowledge freely and always keep our eye on the future of our planet and our people.