Wednesday, July 17, 2019

Plastic 2.0 – Roadmap to a plastic super economy


The menace of single use plastic is growing at a pace far higher than IPv6 enabled IOT devices or advances in semiconductor or nanotechnology. At one side, science is growing to newer horizons tackling many of the problems we inherited. But on the other side, science is also trying to catch up to finding solutions for the problems we created. In the last two decades, the availability and applicability of single use plastics has grown to over 200 times (sic). A byproduct of the hydrocarbon industry (crude oil), plastic has revolutionized our way of life for the good, bad and ugly. While the world over is slowly changing our energy source from Hydrocarbons to other environmentally sustainable sources, it is only natural that we should start finding ways to reduce the use and dispose of plastics. Photographic evidences of uninhabited Henderson islands[1] in the middle of Pacific littered with plastic waste and Albatross caraccas with plastic inside the body[2] are defining moments that should open our eyes and thoughts to start finding solutions to the real-world problems.
Figure 1: Plastic littered beach, Henderson Islands
Figure 2: Plastic from a dead Albatross
The solution is simple, reduce use of plastics and recycle them to clean the mess we have created. It is not the ‘what’ that is perplexing, it is the ‘how’, ‘who’ and ‘when’. To answer the most important of these on ‘who’ – well I don’t know of an alien species that will come and do this for us. And for the ‘when’, we already missed the bus. But let’s try to run up and catch it.
Before going to the ‘how’, let’s have a quick look on other global initiatives undertaken and how countries like India can turn the tide over. We will take the most recent example of reduction in the tariff for photovoltaic cells that lead economies like India to take a leap and the global Solar energy production to shoot over its own projection by manifolds. Back in 2015 during the Climate convention in Paris (COP21), a reluctant India became the make or break factor in getting the Paris Agreement ratified. India had the intent to reduce on Carbon emissions but was reluctant to sign the accord before an alternate cheaper solution to its growing energy needs was available. Everyone knew Solar Energy is one of the key substitutes, but it wasn’t cheap then. The cost of import was tremendously high and there were no companies willing to do a technology transfer that will let India be self-reliant for manufacturing Solar panels in India. At last India agrees to sign the accord following an assurance of having the IP rights from Solar City (it’s an Elon Musk company) and a low interest long-term load from World Bank specific to installing rooftop solar panels. India also pledges to have an installed capacity of 100GW by 2022. It was a win-win for everyone. The prices of Photovoltaic films have come down from around $7 per Wp of Solar Power in 2007 to less than $1 in 2018[3]. Likewise, the installed capacity during the same period increased from 100 GW to 1 TW[4]. And, India is one of the biggest Solar markets and the projection of 175 GW by 2022 will in most probability be surpassed. Developing economies like India, can make a difference globally.
India is also a world leader in micro-retailing – a phenomenon where FMCG products in very small quantities are sold at affordable prices to the masses. Hair Oil & Hair Shampoo sachets at ₹1, mouth fresheners at ₹2 and fried snacks at ₹5 are few examples. The sachets are made from single use plastics and if you have been once to India, you will notice shiny packets all along the roadsides. While the concept of micro-retail is a relief for most of the population with lower purchasing power, the environmental impacts the discarded packing materials throw is beyond manageable. Such single use plastics would easily make for the largest chunk in the landfills and our plastic waste problems. It is with these backgrounds I want to try and suggest on a few ways on the ‘how’ – how to tackle the single use plastic waste issue polluting the whole world, including the marine ecosystems.
Figure 3: A meme on plastic in Sea-food


The root cause of the issue lies in the high availability of plastics at dead cheap prices. From 2 million tons of plastic in 1950, we have grown to produce 381 million tons in 2015; annual production increasing by 200 folds[5]. Plastics come from Crude and an estimate 6% of fuel is used to generate plastics. While the global crude oil prices once peaked to $130 a barrel, the avg. cost of producing a ton of plastic has been decreasing over the years. That is the foremost reason why you no longer find your favorite Cadburys wrapped in paper. Nor your toothpaste coming in Aluminum cans or your milk in bottles. While plastics is convenient and costs less, the price we pay outplays them both.
Government of India has tried many times to bring in legislation aimed at reducing the plastic usage. The recent ban in Maharashtra in 2018 where all Retail shops (at least the medium to big ones) stopped providing plastic carry bags and switched to cloth or other biodegradable materials. It started off well but soon veered off the runway. Retail chains have started using plastics (they may be beyond the 50-micrometer threshold, but still is plastic) for retail packaging, but still sticks to the carry bags made of cloth. Even then, many products like milk could be in plastic bags. This was a clear message – that we lack the intent and whatever we were doing was only namesake. This must change and now. We need to regroup, rethink, re-strategize and re-invent.
Figure 4: National Geographic Cover
Challenge the Status-quo: First thing first, plastic cannot be this cheap given the price we are paying. There are already many grades of plastic available for various uses. A few regulations should be brought that will make virgin plastics manifold costlier than recycled plastics. This is intended to make the industries re-strategize on their product packing and limit virgin plastics to critical uses like for medical equipment, automobile industry etc. and, make the petroleum industry rethink on their business model around plastic. When presented with a challenge that will shake the business foundations, industries always have come up with innovation. It is the go-easy attitude we have on plastics that’s letting the industry on its current course.
Food packaging: Just as the Automobile industry was regulated for CO2 emissions and asked to upgrade their line up to BS6 standards, we need to have a phased approach to phase-out single use plastics by the year 2030 (yes, we don’t have much time and we need to act fast before the world become one big landfill). Canada aims to ban single use plastics by 2021[6].  Start with labeling plastics as virgin or recycled (with % or recycled plastic used). The Food Safety Regulator (FSSAI) can start by imposing a food package policy that will lay out clear guidelines on what materials can be used for packing FMCG food and dairy products. For products with shorter shelf life, like milk, we need to go back to glass bottles with a buyback policy. Let the scientific community mull on the real need to have so much of food-grade plastic for packaging. Why cannot we use semi-recycled or fully-recycled plastic to package dry-food items like bread and biscuits? Cakes and other bakery products, chocolate bars need to be packed in double – butter paper inside and paper outside.
Beverages: This is far more challenging as use of aerated, sugary, alcoholic beverages are on the rise and we don’t seem to have any concerns on the health hazards. Nevertheless, we need to have clear strategies on reducing the impact PET bottles cause to nature. When I watch videos of large scale plastic recycling, the one thing that stands out is the printed brand label. Getting them off the bottle before shredding the PET bottle for recycling is important as both are different grade plastics. The PET industry needs to come up with innovative solutions to replace these plastic labels altogether. Brands emblems and product name engraved on the bottle body, printing directly on them like they dot-print the prices and manufacturing date etc. can be some of the ways. Such bottles should be made easier to recycle.
Sorting at Source: Responsibility of managing the plastic wastes must lie with the user and we need to do more than just throw them as trash. It’s not the manufacturer and certainly not the government or any other local bodies/NGOs who has to clean the mess. Yes, the government needs to create laws to regulate use and dispose of plastics, and ensure they are implemented. But is high time the people own this. Think about it, why would someone pick your waste and dump them afar for you? While it may help clean your surroundings, but isn’t the dumpsite in the Earth too? how long can we continue to look away and hope someone will do it? Recently, media reported of a Japanese Town that has become zero-waste[7]. The residents wash, sort and pack the wastes in 34 categories and even take them to the town’s sorting centers where 80% of them are recycled. They made tremendous progress since this was enacted in 2003. While it may sound difficult at the beginning, this becomes a way of life. And cities cannot really afford to keep doing the way we are doing now, this is not a sustainable way to deal with our wastes. Many cities now have a sorting mechanism where dry and wet wastes are collected separately, though I doubt the effectiveness. Such works are outsourced to vendors who collect them and take to a processing facility or a landfill. Households, housing societies/colonies etc. need to step up. Take for example the simple milk packets. They must be washed, dried and stored before disposing. In cities, housing societies can play a crucial role. Many housing societies already have wet waste compost pits and make bio-composts, some even market them. Going a step further, they need to have plastic shredders installed to shred sorted plastic to different categories and only dispose them to designated waste management companies. The can reclaim the shredding costs from the recycling companies who would pay them for the clean, sorted and shredded recyclable plastic. Housing societies can even sell these to the highest bidder. For smaller towns/villages, these needs to be done at a ward/panchayath/village level with fortnightly or monthly waste collections. Waste collection companies shall not accept any untreated/sorted wastes; if they must, they need to do it on a premium cost.
Sorting at source also serves another purpose – it saves space. The current landfills are dump yards where wastes are dumped without processing. They eat space and causes irreversible environmental impacts. Compressing, shredding etc. makes plastic wastes not only easy to recycle but also requires far less space.
Figure 5: Shredding machine (small)
Moving to a Plastic Economy: Regulations mentioned above aim at making virgin plastic less accessible and encouraging recycling. With supply of virgin plastics reduced, industries will be forced to work on recycling plastics. World over, enthusiasts, entrepreneurs, environmental activists, conservationists, scientists have found ways to make use of plastic wastes in variety of ways. Some of them includes using plastic wastes for roads, recycled products (RPET), using as Carbon source in the recycling of crap steel, electricity generation using IGCC (Integrated Gasification Combined Cycle), making filaments for 3D printers etc[8]. Dr. Madhu S of Highway Research Institute of India has formulated a road surface including plastic wastes along with the usual products to make roads that are more rain resistant and durable. I am compelled to imagine on the positive impacts a nation-wide regulation can bring in mandating use of plastics in road construction. Our current Minster for Road Transport & Highways is a vocal proponent of this idea and I see no reason this should not be implemented. Another area that can bring in wider impact is construction industry. Recent developments show promising use of plastics in Roofing Tiles, Concrete, Indoor Insulation, Structural Lumbar, PVC windows, Bricks and Fences[9] among others.
And that leads to the exciting front of developing a plastic-based economy serving global markets. We have produced enough wastes already to serve every road to be built/repaired, all civil constructions to ever take place. India can take a lead if we formulate the right policies and have enough Budget for more R&D into Plastic Recycling and subsidies to Recycling industries, India can become a net-exporter of recycled plastics. Waste collection, segregation, shredding & recycling etc. can provide employment and support small-scale industries. The potential is high, we only need an intend and will to see it through.