Why PVC-Free is Gaining Momentum

This article first appeared in the December issue of Digital Image Magazine

PVC-Free is the new buzzword in the sign and print industry when it comes to promoting materials as sustainable alternatives. If it’s PVC-Free, it is implied to be eco-friendly and a better environmental choice. But PVC-Free simply means that the product does not contain PVC. It offers no other explanation about the product and requires no other credentials other than not being PVC. Is PVC so bad that anything else is a better choice?

Why is PVC considered to be the problem plastic?

PVC is the third most used plastic in the world, with about 40 million tons produced each year globally. Predictions are that by 2025 this could increase to 60 million tons. PVC is the most common type of plastic used in our industry. It is cheap and, when mixed with other ingredients, produces several functional and performance benefits that are hard to beat. PVC film is incredibly versatile, conformable, moisture and chemically resistant, fire retardant and durable, features that make it an ideal substrate for graphics. The flip side is that from a health and environmental perspective, PVC has been dubbed “the poison plastic “.

Of all the different types of plastic, PVC is considered the most toxic and challenging to dispose of. This presents a significant challenge for our industry. On the one hand, there is growing demand and pressure from customers to provide more sustainable solutions, but equally, customers want quality, high-performing graphics at cost-effective pricing. Sustainability is important, but so is staying in business.

What exactly is PVC?

PVC is a thermoplastic that is made from salt and oil. The electrolysis of saltwater produces chlorine, which is combined with ethylene extracted from petroleum. This produces vinyl chloride monomer (VCM), which is then polymerised to produce PVC polymer. It is not the use of non-renewable fossil fuels that is the major problem. Plastic production only accounts for around 4% of fossil fuel demand. The issue is in the composition of PVC. For starters, VCM is classified as carcinogenic. This is more of an occupational exposure concern during the processing and production of the material than in the day-to-day handling during the production of graphics. For PVC to be of any use to us as a substrate, it needs to be mixed with additives. These additives determine the functionality and characteristics of the final PVC product. They also contribute to the toxicity and environmental threat associated with PVC. Phthalates (plasticisers) are added to PVC to make it soft and flexible. Phthalates are endocrine disruptors that interfere with hormone activity and production in humans and animals. Plasticisers do not chemically bond to the PVC polymer, so they are prone to migration; how much and at what point depends on the type, quality, and conditions. Some film manufacturers have moved towards non-phthalate plasticisers or minimised levels to meet health and safety regulations. Other additives can also have varying health and eco impacts depending on the types and quantities used.

While the impact of PVC can be managed with appropriate measures during manufacturing, the problems really come when PVC starts to break down in the environment or when we try to dispose of it. It is here where PVC releases its ingredients, chemicals, and additives into the atmosphere.

The incineration of PVC is problematic. PVC is an inherently self-extinguishing fire-retardant material due to the high percentage of chlorine. The downside is that when PVC does burn, it releases hydrogen chloride gas which is highly toxic. As a waste solution, incineration of PVC produces dioxins and furans that need to be carefully managed to ensure the resulting toxins are contained. Incineration and waste to energy are not 100% zero waste solutions. What is left is ash which still contains the contaminated waste and requires disposal in landfill.

In landfill, as PVC breaks down, it will leach its additives. While this does not present a problem if the landfill is managed and contained, landfills do not stay that way forever, and eventually, their contents will leach out into the surrounding soils and waterways.

Right now, recycling in Australia and New Zealand is not a viable option for PVC graphics.

At the very least, we should ensure that no PVC films are left to degrade in the environment. All PVC graphics should be removed before they start to flake off into the atmosphere.

It is clear that the available methods to deal with PVC waste in our region are not adequate. If we are unable to make progress in waste management, then we seriously need to consider moving to materials that are less damaging and more easily disposed of.

 This is why there is an increasing shift towards PVC-Free films. As an industry we should be looking at where we can reduce and replace PVC without compromising graphic performance or commercial reality.

Written by Denise Kirby

Denise Kirby, has over 25 years experience in the sign industry as a supplier of self adhesive products. Initially starting out in a family business as a distributor of Mactac products to sign and print companies, Denise has worked for Mactac Europe in a business development and marketing roles across Australia and New Zealand, as well as Avery Dennison, when they bought Mactac.

Denise is highly passionate about the industry and enjoys writing about different applications and opportunities with the hope of inspiring people to explore new creative and functional opportunities with film.