Minimum GHG emissions and energy consumption of U.S. PET and polyolefin packaging supply chains in a circular economy

Chaudhari, Utkarsh S.; Patil, Abhishek; Hossain, Tasmin; Watkins, David W.; Hartley, Damon S.; Reck, Barbara K.; Handler, Robert M.; Johnson, Anne T.; Thompson, Vicki S.; Shonnard, David R.

doi:10.1039/D5SU00284B

Minimum GHG emissions and energy consumption of U.S. PET and polyolefin packaging supply chains in a circular economy

Journal Article · Mon Jun 02 00:00:00 EDT 2025 · RSC Sustainability

DOI:https://doi.org/10.1039/D5SU00284B· OSTI ID:3013355

^[1]; Patil, Abhishek ^[1]; Hossain, Tasmin ^[2]; Watkins, David W. ^[1]; ^[2]; ^[3]; Handler, Robert M. ^[1]; Johnson, Anne T. ^[4]; ^[2]; ^[1]

Michigan Technological Univ., Houghton, MI (United States)
Idaho National Laboratory (INL), Idaho Falls, ID (United States)
Yale Univ., New Haven, CT (United States)
Resource Recycling Systems (RRS), Ann Arbor, MI (United States)

There is a wide agreement on the urgency of transforming linear management of plastics towards a circular economy model. However, no clear pathways exist as to required recycling technologies involved and system-wide environmental impacts. This study explores such pathways in the U.S. for the most commonly used packaging plastics through a combination of mechanical and emerging advanced recycling technologies. A system optimization model aimed at minimizing environmental impacts was developed to determine optimal end-of-life (EOL) management and locations of existing and emerging U.S. recycling infrastructures. Our study includes material flows from virgin resin production through semi-manufacturing processes to existing EOL disposal and recycling processes. An optimized circular plastics packaging system achieved greenhouse gas (GHG) emission savings of up to 28% and cumulative energy demand (CED) savings of up to 46%, compared to the linear economy. Moreover, these savings of GHG emissions and CED impacts represent a reduction of 0.16% and 0.49% compared to annual U.S. GHG emissions and energy consumption in 2022, respectively. The optimal recycling rates and systems-level circularity ranged from 78–99% and 57–75%, respectively. Increased energy savings led to increased GHG emissions showing a potential trade-off between GHG emissions and energy. Analysis of 40 scenarios showed the importance of material collection distances, blend limit of mechanically recycled resins, process yields, and mandated recycling rates for achieving a sustainable circular economy of plastics.

View Accepted Manuscript (DOE)

Research Organization:: Idaho National Laboratory (INL), Idaho Falls, ID (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Nuclear Energy (NE)

Grant/Contract Number:: AC07-05ID14517; EE0007897

OSTI ID:: 3013355

Report Number(s):: INL/JOU--25-85523

Journal Information:: RSC Sustainability, Journal Name: RSC Sustainability Journal Issue: 7 Vol. 3; ISSN 2753-8125

Publisher:: Royal Society of ChemistryCopyright Statement

Country of Publication:: United States

Language:: English

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Related Subjects

09 - BIOMASS FUELS
PET
circular economy
plastic
polyolefins
supply chains

Minimum GHG emissions and energy consumption of U.S. PET and polyolefin packaging supply chains in a circular economy

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