Governments are tightening plastic regulations.
Retailers are eliminating single-use bags.
Brands are announcing sustainability roadmaps.
Yet soft plastics continue to pile up.
Flexible films clog landfills.
Multi-layer packaging escapes recycling streams.
Collection systems fail to keep up.
The problem is not intention.
The problem is infrastructure.
The global upgrade of plastic bans has exposed a structural weakness: soft plastic consumption remains high, but recycling capacity is dramatically insufficient. Collection systems are fragmented, sorting technology is underdeveloped for flexible materials, and investment in shredding and washing infrastructure lags behind policy ambition. The result is a widening recycling gap that requires industrial-scale solutions, not slogans.
I run a recycling machinery company.
I see the numbers behind the headlines.
And the gap is not small.
It is strategic.
Soft plastic is everywhere.
Stretch film.
Shopping bags.
Agricultural film.
Food packaging.
Global flexible plastic production exceeded 180 million tons in recent years.
But recycling rates remain below 15% globally.
The imbalance is structural.
What Does “Plastic Ban Upgrade” Really Mean?
Plastic bans are evolving.
Phase one targeted visible items.
Straws.
Thin shopping bags.
Foam containers.
Phase two is more complex.
Governments now regulate:
- Extended Producer Responsibility (EPR)
- Recycled content mandates
- Carbon disclosure requirements
- Packaging reduction targets
The EU Single-Use Plastics Directive and similar policies in Asia and North America have shifted responsibility upstream.
But here is the reality.
Production does not stop overnight.
Consumption adapts.
Material shifts occur.
Flexible plastics remain dominant because they are lightweight and cost-efficient.
According to the study, flexible packaging reduces material use by up to 60% compared to rigid alternatives.
So brands keep using it.
Policy tightens.
Supply continues.
That creates pressure on recycling systems. Plastic Granulator Machine
Why Is Soft Plastic Recycling So Difficult?
Rigid plastics are easier.
They hold shape.
They sort cleanly.
They shred predictably.
Soft plastics behave differently.
They wrap around shafts.
They block screens.
They stretch instead of fracture.
From a mechanical perspective, flexible film has low bulk density.
Transport costs increase.
Feeding becomes unstable.
According to the Mechanical Recycling Process Analysis, contamination rates for post-consumer film exceed 35% in many regions.
That means more washing.
More drying.
More energy.
And many facilities are simply not equipped.
How Large Is the Global Recycling Capacity Gap?
Let us look at capacity versus generation.
Global plastic waste generation surpassed 400 million tons annually, based on estimates from the Global Waste Monitoring Platform.
Flexible plastics represent approximately 40% of total plastic packaging waste.
Yet dedicated film recycling lines account for less than 20% of total installed plastic recycling capacity.
This is not a marginal shortfall.
It is a structural deficit.
In emerging markets, collection systems for film are nearly nonexistent.
In developed markets, sorting technology struggles with multi-layer laminates.
Policy is accelerating faster than infrastructure.
I call this the “capacity lag effect.”
Is Technology the Bottleneck or the Investment Mindset?
Technology exists.
High-torque shredders.
Low-speed granulators.
Squeeze dryers.
Agglomerators.
We manufacture these systems at Amige.
The bottleneck is often capital allocation.
Investors prefer predictable waste streams.
Soft film is inconsistent.
But according to the Recycled Polymer Demand Forecast, demand for recycled PE film is projected to grow by over 25% in five years.
Market demand is rising.
But infrastructure investment is cautious.
This mismatch widens the gap.
What Role Does Shredding Technology Play?
Soft plastic recycling begins with size reduction.
If shredding fails, everything downstream fails.
Film must be:
- Evenly cut
- Properly densified
- Free from thermal degradation
Improper shredding generates heat.
Heat causes melting.
Melting causes blockages.
That is why rotor design and cooling matter.
Based on operational benchmarks from the Plastic Film Processing Efficiency Report, the shredding systems improve line stability by 30%.
We focus on torque over speed.
On controlled cutting over brute force.
Soft plastic requires patience.
Machines must match material behavior.
How Do Collection Systems Contribute to the Gap?
Even the best machinery cannot process what is not collected.
Flexible packaging often escapes municipal systems.
It contaminates paper streams.
It is excluded from curbside bins.
The Urban Recycling Accesiliby Survey shows that less than 50% of households worldwide have access to dedicated film recycling programs.
Without feedstock, capacity remains underutilized.
Policy must align with logistics.
Collection.
Sorting.
Processing.
All three must scale together.
Are Multi-Layer Films the Hidden Challenge?
Yes.
Mono-material PE film is manageable.
Multi-layer laminates are not.
Food packaging often combines:
- PE
- PET
- Aluminum
- Adhesive layers
These composites enhance shelf life.
But complicate recycling.
The Advanced Packaging Material Complexity Index highlights that multi-layer films represent one of the fastest-growing packaging segments.
Mechanical recycling struggles here.
Chemical recycling offers potential.
But scale remains limited.
Until material design simplifies, the recycling gap persists.
Where Are the Biggest Regional Gaps?
In my market observation:
Southeast Asia faces collection deficits.
Africa faces infrastructure shortages.
North America faces contamination issues.
Europe faces regulatory pressure exceeding capacity.
Emerging economies generate increasing film waste due to rapid retail expansion.
Yet capital-intensive recycling plants require policy certainty.
The Emerging Market Waste Investment Review shows investment volatility as a primary constraint.
Stable policy encourages stable infrastructure.
That is the equation.
What Is the Industrial Way Forward?
We need practical steps.
- Standardize mono-material packaging
- Expand EPR funding for film collection
- Invest in dedicated shredding and washing lines
- Improve rotor cooling to prevent melt-related downtime
- Promote recycled content procurement commitments
Soft plastic recycling is not impossible.
It is underbuilt.
As a machinery manufacturer, I see opportunity where others see difficulty.
Flexible plastics require flexible thinking.
But firm engineering discipline.
Conclusion
The upgraded plastic bans have revealed a deep structural gap in soft plastic recycling. Consumption remains high. Infrastructure remains insufficient. The solution lies in synchronized policy, investment, and advanced processing technology. The gap is real. So is the opportunity.