Toward Film-to-Film Recycling

Kao’s efforts to contribute to solving global plastic issues also include designing packaging that is easier to recycle, researching recycling technologies, and developing packaging made from recycled plastics.

Refill packaging, which uses significantly less plastic than traditional packaging, is made from multiple layers of composite materials to protect various contents from risks such as damage in transport or risks in the storage environment such as ultraviolet rays. Therefore, when recycled it becomes a non-uniform plastic made of various elements, making it difficult to recycle back into refill packaging. Until now, such non-uniform plastics have been recycled into pallets used when transporting goods using forklifts, and into fake wood.

In order to use these refill packs, which are difficult to recycle at such a high level, as raw materials, we have been researching recycling technologies at a pilot plant for film packaging recycling, which was introduced at the Wakayama Research site in June 2021. We have been conducting research to realize film-to-film recycling of refill packs back into refill packs, and in May 2023, we launched a product making partial use of recycled materials to produce the same type of packaging by recycling used refill packs.

An illustration of a multi-layered film container, as an example, from the outside of the container, thin films are stacked in this order: substrate layer, printing layer, adhesive, barrier layer, adhesive, and bonding layer to form the container.

Cross section image of film

A magnified image of the recycled film without resin modification, because refill packs are made from multiple types of materials, they are uneven, have holes, etc., and cannot be made into film.

Non-uniform recycled film

A photo of a prototype of recycled film with modified resin.

Recycled film with modified resin

Completion of film-to-film recycling research plant at Wakayama site

In 2021, we launched an experimental plant. The ultimate goal is to realize film-to-film recycling – making packaging from packaging. We will continue to pursue the realization of a sustainable circular society.

A image of the product with recycled refill pack launched in May 2023 and a cross-sectional view showing its structure. Recycled resin was used sandwiched between the inner polyethylene layer of the container.

The product with recycled refill pack launched in May 2023. Recycled resin is used for the inner layer of polyethylene.

Kao becomes the first manufacturer or retailer to receive approval for voluntary collection of plastic packaging from consumers in Japan under the plastic resource circulation act

In March 2024, Kao Corporation and Group company Kao Transport and Logistics Company Limited received approval from the Ministry of Economy, Trade and Industry and the Ministry of the Environment for voluntary collection by a manufacturer or retailer related to collection of plastic packaging at Kao business locations and in Kamakura City. This is the first such approval received by a manufacturer or retailer for collection from the general public. This approval system is a measure related to implementation of the Act on Promotion of Resource Circulation for Plastics (Plastic Resource Circulation Act) that went into force on April 1, 2022. With this approval, Kao and Kao Logistics are able to collect used refill packs within the Kao Group and in the city of Kamakura without needing to obtain service permission under the Act on Waste Management and Public Cleaning (Waste Management Act).

Until this time, used refill packs have been collected as “valuables” in these areas, but the certification will allow collection as “waste”. In the future, we may be able to speedily expand the collection area by increasing the number of certified routes through similar applications and notifications in other regions. In addition, by utilizing existing inter-site transportation services, transportation costs and environmental impact will be reduced.

Kao announces its participation in “Kobe Plastic Next: joining forces to recycle refill packs, a project aimed at Horizonal recycling of refill packs”

We are involved in a project in which the city of Kobe and 16 corporations work together to realize resource circularity. Through collaboration with the return journey of deliveries for retail stores and recyclers, we are carrying out collection efficiently while minimizing environmental impact. Also, in addition to upcycling collected refill packaging into items useful in daily life, we are aiming to realize film-to-film recycling in which they are recycled back into refill packaging.

The “RecyCreation” Initiative

The “RecyCreation” Initiative

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