Plastic is an integral part of modern society, deeply ingrained in our daily lives due to its versatility, affordability, and convenience. From packaging to construction materials, electronics to medical devices, plastic has revolutionised countless industries, offering unparalleled functionality and durability.
However, the widespread use of plastic has also brought significant environmental challenges. The durability that makes plastic so useful also means that it can persist in the environment for hundreds of years, leading to pollution of oceans, rivers, and landscapes. Single-use plastics, in particular, have come under intense scrutiny for their role in environmental degradation.
There has been a growing movement towards more sustainable practices in the plastic industry. As a first step towards adopting the movement, this blog breaks down the differences between the two main types of plastic:
- Post-consumer-recycled plastic (PCR)
- Virgin Plastic
What is PCR?
Post-consumer recycled Plastic, or PCR, is derived from plastic products that have already been used and discarded by consumers. These products are collected through various recycling programs, sorted, cleaned, and processed into raw materials that can be used to create new plastic products.
Benefits of Using PCR
- Environmental Impact: One of the most significant benefits of using PCR is its positive environmental impact. By recycling post-consumer plastic, we reduce the amount of waste that ends up in landfills and oceans, helping to mitigate the pollution and environmental degradation caused by plastic waste.
- Resource Conservation: PCR helps conserve valuable natural resources. The production of virgin plastic requires significant amounts of petroleum and natural gas. By using recycled materials, we can reduce the demand for these finite resources, promoting a more sustainable approach to plastic production.
- Energy Efficiency: The process of recycling plastic generally consumes less energy compared to producing virgin plastic from raw materials. This energy savings translates into a reduction in the overall carbon footprint, contributing to efforts to combat climate change.
- Enable Circular Economy Practices: Plastic recycling ensures that plastic is diverted away from landfills and oceans and returned to the economy, creating a true circular loop, where one person’s waste is another’s resource.
What is Virgin Plastic?
Virgin Plastic, on the other hand, refers to plastic made from raw materials derived from fossil fuels, such as petroleum or natural gas. Unlike PCR, which uses existing plastic waste, virgin plastic is produced through a manufacturing process that involves extracting and refining crude oil or natural gas to obtain the raw materials needed for plastic production.
- Extraction of Raw Materials: The production of virgin plastic begins with the extraction of raw materials, primarily crude oil or natural gas. These resources are obtained through drilling and mining activities, which can have significant environmental impacts, including habitat disruption, oil spills, and greenhouse gas emissions.
- Refining and Cracking: The extracted crude oil or natural gas is transported to refineries, where it undergoes a process called cracking. Cracking breaks down the large hydrocarbon molecules into smaller molecules, such as ethylene and propylene, which are the building blocks for plastic production.
- Polymerisation: The small molecules produced during cracking are then subjected to polymerisation, a chemical process that links them together to form long polymer chains. These polymer chains are the primary components of plastic resins like polyethene, polypropylene, and polystyrene.
- Pelletisation: The resulting plastic resin is cooled, solidified, and cut into small pellets. These pellets, known as virgin plastic pellets, are then packaged and shipped to manufacturers who use them to create a wide range of plastic products.
While virgin plastic has been the dominant form of plastic used in manufacturing for decades, its environmental impact has increasingly been scrutinised. The extraction and processing of fossil fuels required to produce virgin plastic contribute to greenhouse gas emissions, habitat destruction, and other environmental harms.
Both types of plastic have distinct environmental footprints, and understanding these differences is essential for making informed choices.
Carbon Footprint – PCR vs Virgin Plastic
Virgin Plastic: The production of virgin plastic involves the extraction and refinement of fossil fuels, processes that are energy-intensive and emit significant amounts of greenhouse gases (GHGs). From drilling and transporting crude oil or natural gas to polymerising these materials into plastic, each step contributes to a substantial carbon footprint.
PCR In contrast, the production of PCR significantly reduces the carbon footprint. By recycling existing plastic, the need for new fossil fuel extraction is minimised, thereby lowering GHG emissions. The process of collecting, sorting, and reprocessing plastic waste consumes less energy compared to producing virgin plastic from raw materials.
Energy Consumption – PCR vs Virgin Plastic
Virgin Plastic: The production of virgin plastic is highly energy-intensive. The entire process, from raw material extraction to polymerisation and palletisation, requires large amounts of energy, primarily from non-renewable sources. This high energy consumption translates to greater environmental degradation and resource depletion.
PCR: Producing PCR requires less energy than producing virgin plastic. Recycling processes, while still energy-consuming, are generally more energy-efficient as they skip the initial stages of raw material extraction and refining. This results in lower overall energy use and a reduced impact on natural resources.
Waste Generation – PCR vs Virgin Plastic
Virgin Plastic: The creation of virgin plastic generates significant waste, including byproducts from the refining and polymerisation processes. Additionally, products made from virgin plastic contribute to the growing problem of plastic waste, particularly when they are disposed of improperly or used in single-use applications.
PCR: Utilising PCR helps mitigate waste generation by diverting plastic waste from landfills and incineration. Recycling post-consumer plastics not only reduces the volume of waste but also extends the life cycle of existing materials. This process promotes a circular economy where materials are continually reused, reducing the need for new plastic production.
Case Study: Coca-Cola’s Use of PCR
“Coca-Cola is committed to its World Without Waste vision by enhancing the sustainability of its packaging. The company plans to increase the use of recycled and renewable materials while decreasing reliance on virgin, fossil-based materials. By 2030, Coca-Cola pledges to collect and recycle the equivalent of every bottle it sells, ensuring no packaging becomes waste. Moreover, the company aims to make 100% of its packaging recyclable and to incorporate 50% recycled materials in its packaging.[1]”
Bottom Line – PCR vs Virgin Plastic
In the versus between post-consumer recycled plastic and virgin plastic, PCR emerges as a more sustainable choice due to its lower environmental impact, reduced carbon footprint, and conservation of natural resources. By opting for PCR, companies can significantly contribute to a circular economy, reducing waste and promoting environmental sustainability. Choosing PCR not only helps in achieving sustainability goals but also aligns with growing consumer and regulatory demands for greener practices.
PCR Mandate on the Horizon?
Upcoming EPR Mandate for Use 10% of Recycled Material in Plastic Packaging
As India moves towards more sustainable practices, upcoming mandates are set further to drive the adoption of PCR in plastic packaging. Extended Producer Responsibility (EPR) schemes are essential to brand owners and producers to achieve a circular plastics economy, transforming waste into a valuable resource to tackle economic, social, and environmental challenges.
New guidelines mandate the following minimum levels of recycled content in plastic packaging:
| Plastic packaging category | 2025-26 | 2026-27 | 2027-28 | 2028-29 & onwards |
| Category I | 30% | 40% | 50% | 60% |
| Category II | 10% | 10% | 20% | 20% |
| Category III | 5% | 5% | 10% | 10% |
Recykal8 can help you achieve these targets easily by providing a reliable platform for sourcing and managing recycled materials efficiently.
Recykal8 is a B2B marketplace developed by Recykal that channels post-consumer recycled materials like PCR resins, PET flakes, fibre, and yarn. By leveraging Recykal8, companies, brands, producers, and recyclers across various industries can effectively integrate PCR into their operations, further promoting sustainability and meeting regulatory requirements. Recykal8 facilitates the seamless movement of materials from waste generators to collection centres and supports the buying and selling of recyclables with comprehensive end-to-end logistics and transaction support.
