The dairy supply chain swears on its cradle-to-grave credentials that it will meet its 2010 recycling commitments under the Milk Roadmap. Paul Gander reports on its progress

It has been said that, faced with recession, retailers will sideline any focus on sustainability in favour of sheer survival. Or could the sustainability agenda itself prove to be the great survivor of the downturn? Over the summer, the progress of last year's Milk Roadmap, specifically the section referring to the use of recyclate in high-density polyethylene (HDPE) bottles, appeared to provide the acid test.

Drawn up by the Dairy Supply Chain Forum (DSCF) in May 2008, the Roadmap spans sustainability goals in areas ranging from greenhouse gas emissions to land management. One of the targets for 2010 is the incorporation of 10% recycled HDPE into bottles for fresh milk.

Earlier this summer, there were persistent suggestions that the industry as a whole may not meet this target. And while Dairy Crest was unilaterally announcing that it would do so, Chris Dow, managing director of HDPE recycler Closed Loop Recycling (CLR), wrote in an article for Packaging News that the drinks industry generally was "in danger of missing major milestones in terms of commitment to using recycled content".

But by August, Dow was reporting that all of the partners were responding "very well, very positively". The DSCF's own report, ‘One Year Down the Road', concluded that the industry would hit the 10% target "by the end of 2010". Although there appears to be some slippage on the original Roadmap's deadline of "by 2010 or sooner", progress is clearly being made.

In fact, while the August DSCF report predicts that around a quarter of milk bottles will meet the 10% target by next summer, HDPE reprocessor Greenstar WES is even more upbeat. Managing director James Donaldson says: "There's a good chance that the industry can hit its target by the end of the first quarter of 2010, certainly in terms of supply capacity."

Safety standards
As for food contact standards, Donaldson points out that Greenstar has been supplying rHDPE to the likes of Linpac and Sharp Interpack for more than a year. The recyclate is used together with polypropylene in meat and poultry trays. "Here, the migration tests are more rigorous," he argues. Since then, Greenstar has begun to supply rHDPE for use in Marks & Spencer's milk bottles and, more recently, Dairy Crest's.

Dairy Crest says that its relatively advanced progress in the use of recyclate reflects its early involvement with Wrap's rHDPE project. But other dairies now say they are well positioned to meet the 2010 deadline.

Arla Foods underlines the practical, rather than quality control, challenges. Project manager Nick Martin says: "We have already supplied milk in 10% rHDPE to customers. But significant investment and infrastructure changes are required to achieve this across the whole business." This summer, Arla's expectation was to begin commercial supply during September.

Meanwhile, Greenstar's Donaldson explains why introducing recyclate is not as easy as it may seem: "There are three stages to the process of supplying rHDPE. Firstly, you make the odd tonne to the required standard. Then you validate the process and undergo the relevant challenge tests to demonstrate removal of potential contaminants. And finally, you have to deliver tonne after tonne with all quality systems working."

So for instance, Greenstar tests hourly production samples for volatile gases, then carries out a full analysis on the lowest-scoring samples. It uses an electronic ‘nose', which is correlated with the findings from taste and odour panels. "This is a gradual confidence-building process, where each partner in the chain has to conduct their own due diligence," Donaldson says.

Greenstar customer Nampak Plastics Europe says that, together with its business partners, it commissioned "rigorous customer trials" with independent testing organisations Pira International, Leatherhead Food Research (LFR) and Fraunhofer IVV.

Tests included taste, migration, bottle rigidity and colour. Andy Baseley, quality and technical director at Nampak Plastics, quotes the taste test as an example of the detailed trials undertaken. "The process involved manufacturing bottles at various rHDPE percentages, along with 100% virgin HDPE bottles as a standard reference. All were then filled, stored at a suitable temperature, and tested at various points throughout their life." The tests were carried out by trained sensory assessors.

Future targets
Another significant player at the converting stage is Alpla UK. Director Malcolm Fitch says: "Our work with HDPE recyclate is progressing in line with the Roadmap. But we're still in discussions with Wrap and other partners, so it would be unfair to make further comment at this stage."

Of course, under the Roadmap, the incorporation of recycled content is not set to stop at 10%. Further rHDPE targets have been fixed: 30% by 2015 and 50% by 2020. Most supply chain partners would claim trialling is already fairly advanced for 30%.

James Crick, business development director at Nampak Plastics, states: "Successful taste tests with up to 30% rHDPE additions have already been carried out. Extensive manufacturing trials will now be undertaken to ensure that there are no major processing issues arising from a higher recycled content." 

Arla's Martin says: "We have carried out the majority of validation work on bottles containing 30% recycled material, so from a food safety aspect this is straightforward." But as he says, long-term viability will hinge on the continued availability of recyclate in sufficient volumes.

This, of course, could be the crux of the issue. But as more food-grade HDPE recycling comes on stream, milk packaging looks set to reach its Roadmap targets - eventually.