The recycling of PET trays is highly challenging. The aim of this paper was to investigate the issues related to the mechanical recycling process and, the correlation between feedstock composition and the quality of the produced rPET. Four feedstocks with different degrees of impurity were mechanically recycled at a laboratory pilot scale. The optical and thermal properties of the rPET products were examined to determine the quality and to seek relations with the starting level of impurities. The final products of the PET trays’ mechanical recycling were found to be affected by the presence of impurities (organics) and multi-material (non-PET) elements in the feedstocks. The rPET products crystallised faster for contaminated feedstocks showed lower molecular mass and higher yellow index values due to thermal degradation. Yellowing is a crucial parameter in assessing the thermal degradation of rPET. Injection moulded samples corresponding to higher contamination levels, reported values of Yellow Index equal to 179 and 177 compared to 15 of mono-PET sample. The intrinsic viscosity decreased from 0.60 dL/g to just above 0.30 dL/g, and losses were more significant for soiled or multi-material feedstocks. A method of improving the final quality would involve the purification of the starting feedstock from impurities.

The compositions of Dutch lightweight packaging waste (LWP) and sorted products named "PET (Polyethylene terephthalate) trays" have been determined on object level. Additionally, the PET trays from both waste types were sorted in 16 categories representing their packaging use and material build-up. The material composition of at least 10 representative trays from each category was determined with chemical and thermal analysis, based on which the average material composition per category was established. Based on this data the average material composition of sorted PET tray products was approximated. The recyclability of the various categories of PET trays was assessed based on their material build-up. The most ubiquitous PET trays in Dutch LWP and sorted products were only found to be suitable to produce opaque recycled PET with mechanical recycling processes. Whereas only some more uncommon PET trays can be used to produce transparent recycled PET with mechanical recycling processes. Depolymerisation is deemed to be a more appropriate recycling process that will allow the production of transparent food-grade recycled PET.

The building and construction industry is a key sector behind the ecological transition in that it is one of the main responsible factors in the consumption of natural resources. Thus, in line with circular economy, the use of waste aggregates in mortars is a possible solution to increase the sustainability of cement materials. In the present paper, polyethylene terephthalate (PET) from bottle scraps (without chemical pretreatment) was used as aggregate in cement mortars to replace conventional sand aggregate (20%, 50% and 80% by weight). The fresh and hardened properties of the innovative mixtures proposed were evaluated through a multiscale physical-mechanical investigation. The main results of this study show the feasibility of the reuse of PET waste aggregates as substitutes for natural aggregates in mortars. The mixtures with bare PET resulted in less fluid than the specimens with sand; this was ascribed to the higher volume of the recycled aggregates with respect to sand. Moreover, PET mortars showed a high tensile strength and energy absorption capacity (with Rf = 1.9 ÷ 3.3 MPa, Rc = 6 ÷ 13 MPa); instead, sand samples were characterized by a brittle rupture. The lightweight specimens showed a thermal insulation increase ranging 65–84% with respect to the reference; the best results were obtained with 800 g of PET aggregate, characterized by a decrease in conductivity of approximately 86% concerning the control. The properties of these environmentally sustainable composite materials may be suitable for non-structural insulating artifacts.

The management of plastic packaging waste needs to be optimized to improve recycling rates. In this article, fourteen categories of non-bottle polyethylene terephthalate (PET) packages were mechanically recycled at laboratory bench scale; the generated data were assessed using a multi-criteria decision analysis (MCDA) approach to identify the categories most suited for the mechanical recycling process from social, technical and legislative viewpoints. Recycling yields varied between 75% and 92% across the 14 categories. The intrinsic viscosity (IV) values of the produced recycled PET (rPET) corresponded to molecular weights ranging from 28,000 to 35,000 g/mol. The MCDA recyclability assessment showed that 7 of the 14 categories (accounting for 72% of the sorted products by mass flow) are often composed of multiple, inseparable materials, resulting in the lowest-quality rPET. Furthermore, only 4 categories (approximately 28% of the categories) were found suitable for closed-loop mechanical recycling. The stakeholders involved in the PET packaging value chain could use these results to support decision-making and the development of a well-organized framework to valorize even the most complex types of plastic waste.