PWMI NewsletterNO

43 2014.4

Plastic Waste Management InstituteJAPAN

Plastic Products, Plastic Waste andResource Recovery [2012]
Background information and notes on the publication of the
Flowchart of Plastic Products, Plastic Waste and Resource
Recovery (2012)
Resin production in 2012 dropped sharply

waste used as cement material and fuel” to thecompared to 2011 as resin exports decreased inquestionnaire in preparing the flowchart for 2012

the face of an appreciating yen and a world(the recipients of the questionnaire were the same

economic slowdown caused mostly by theas those of the 2011 flowchart). The results ofEuropean sovereign debt crisis, and as resinthat question were tabulated and reported asimports increased and production-plant problems“densified-refuse derived fuel and cement

occurred.

material/fuel” in this flowchart.

Plastic waste used as raw material or fuel in

Plastic Waste Management Institute would likecement factories has been reported as “densified-

to extend its deep appreciation to the Ministry ofrefuse derived fuel” in all flowcharts up to 2011

the Environment (MOE), Ministry of Economy,

based on the results of annual questionnaires.

Trade and Industry (METI), various local

However, it has been found that about 400 kt ofgovernments, and related organizations for theplastic waste other than densified-refuse derived

valuable data and useful advice that they

fuel had also been used as cement material andgraciously provided during the course of thisfuel, so we added the item “amount of plastic

survey.

2012 Highlights(1) Resin production dropped by 1050 kt (-9.1%) relative to 2011 and fell below 11,000 kt for the first time in 25 years.
Domestic plastic products consumption as well dropped by 260 kt (-2.7%).
(2) Total plastic waste discharge decreased by 230 kt (-2.4%) relative to 2011 to 9,290 kt.
(3) For the reasons described above, densified-refuse derived fuel and cement material/fuel increased by 420 kt(+65.5%). As a result, the energy recovery rate increased by two points while the effective plastic utilization rate also
increased by two points over the previous year to 80%.
In 2012, resin production decreased sharply torecycling*1 decreased to 2,040 kt (-90 kt; -4.2%) and

10,540 kt (-1,050 kt relative to 2011; -9.1%), while

increased to 380 kt (+20 kt; +4.4%), respectively.

resin export and product export also decreased to

The portion applied to energy recovery*2 increased

3,420 kt (-480 kt; -12.4%) and 800 kt (-70 kt; -7.8%),

overall to 5,020 kt (+60 kt; +1.3%).

respectively. On the other hand, resin import and

The percentage contributions to the effective

product import increased to 2,470 kt (+200 kt;

plastic utilization rate by mechanical recycling,+8.9%) and 1,880 kt (+30 kt; +1.5%), respectively.

feedstock recycling, and energy recovery were 22%,

As a result of the above, domestic plastic products

4%, and 54%, respectively, showing that energy

consumption decreased to 9,600 kt (-260 kt; -2.7%).

recovery increased by two points and that the plastic

Total plastic waste discharge decreased to 9,290 kt

utilization rate increased by two points overall to(-230 kt; -2.4%). Plastic waste discharge can be
broken down into domestic (general) plastic waste at

80% relative to 2011.
Exports of plastic waste for mechanical recycling

4,460 kt (-190 kt; -4.0%) and industrial plastic waste

increased to 1,670 kt (+40 kt; +2.6%).

at 4,820 kt (-40 kt; -0.8%).

*1: feedstock recycling = blast/coke furnaces + gasification +liquefaction*2: energy recovery = densified-refuse derived fuel and cement
material/fuel + incineration with power generation +incineration with heat utilization facility

In terms of disposal and recovery methods, theportion of total plastic waste discharge (which
decreased by 230 kt from 9,520 kt to 9,290 kt)
applied to mechanical recycling and feedstock

Explanation of flowchart items(1) Resin production, resin processing, andmarketing of products
1-1 Resin production
This figure was determined on the basis of chemicalindustry statistics from the Ministry of Economy, Tradeand Industry (METI).
1-2 Reclaimed products
For convenience sake, the figure used here as input is thatof mechanical recycling from the previous year taking
figures for export and import of plastic waste into account(Ministry of Finance, trade statistics).
1-3 Domestic plastic products consumption
・(Domestic plastic products consumption) = (Resin

2

production) - (Resin export) + (Resin import) - (Liquid
resin, etc.) - (Resin processing waste) + (Reclaimed
products) - (Product export) + (Product import)
・Resin export and import figures are based on trade
statistics from the Ministry of Finance.
・Figures for liquid resin, synthetic fiber, etc. that falloutside plastic waste discharge are based on chemicalindustry statistics from the Ministry of Economy, Trade andIndustry.
・Figures for plastic product export and import are basedon trade statistics from the Ministry of Finance.
・Figure for processing waste considers discharged wastefrom the processing step that is not turned into products.

1-4 Domestic plastic input
・(domestic plastic input) = (domestic plastic products
consumption) – {(exported plastic parts from assembled
products) – (imported plastic parts from assembled
products)}
・Assembled products: automobiles, home appliances(televisions, refrigerators, freezers, air conditioners,
washing machines and dryers)
・Number of exported/imported assembled products:
Automobile figures are based on Monthly Motor Vehicle
Statistics of Japan from Japan Automobile Manufacturers
Association (JAMA); home appliance figures are based on“Current Production Statistics” from Ministry of Economy,
Trade and Industry (METI).
(2) Discharge
2-1 Post-use products discharge
・This figure is determind by an estimation systemdeveloped by PWMI based on usage quantities by demandgenerating fields and by resin type (usage quantities havebeen calculated annually from 1976) and on productlifetimes by demand-generating fields (using a PWMI
discharge model for the last 60 years)
・Since the export of used automobiles affects the amountof plastic waste in Japan, corrections are made to plastic
waste discharge in the transport industry. Here, the numberof used automobiles is based on “number of post-use
automobiles” issued by JAMA and the number of exported
used automobiles is based on data released by Japan
Automobile Dealers Association (JADA).
・Discharge ratios for domestic waste and indust-rial waste
have been estimated using a PWMI discharge model for
demand-generating fields.
2-2 Production and processing waste discharge
・Amount of production waste is not included in am o u n tof resin production, and amount of processing
waste is extrapolated from the re-sults of questionnaires.
2-3 Total plastic waste discharge
・(total plastic waste discharge) = (post-use products
discharge) + (resin production waste) + (resin processing
waste)
2-4 Breakdown of total plastic waste discharge by resin
type
・These breakdown figures were estimated from amounts
for post-use products discharge, production and processing
waste discharge, breakdown of resin production, etc.
(3) Disposal and recovery
3-1 Mechanical recycling
・Figures for the mechanical recycling of domestic plastic
waste are based on the volume of collected PET bottles(The Council for PET Bottle Recycling) and volume ofcollected white trays (Japan Plastic Food Container
Industry Association), and figures for the mechanicalrecycling of other plastic containers and packaging are
based on data released by The Japan Containers And
Packaging Recycling Association. From this year on,
residual amounts after the mechanical recycling of otherplastic containers and packaging will be allocated todensified-refuse derived fuel and other items using figures
released by The Japan Containers and Packaging Recycling
Association as coefficients. (In previous years, residual
amounts were all allocated to landfilling.)
・Total figures and breakdowns for the mechanicalrecycling of industrial waste are extrapolated from theresults of questionnaires sent to recycling companies.
3 - 2 D e n s i fi e d - re f u s e d e r i v e d f u e l , l i q u e f a c t i o n ,gasification, blast furnace raw material
・Figures for liquefaction, gasification, blast furnace raw
materials, and coke-oven chemical materials approved as
product recycling procedures by the Containers andPackaging Recycling Law have been determined on thebasis of bids announced by the Japan Containers andPackaging Recycling Association and results of questionnaires.
・The figure for densified-refuse derived fuel includes
energy recovery as cement kiln fuel and power-generation.
3-3 Disposal and recovery of domestic waste
・Incineration/landfilling ratio
This ratio is determined on the basis of past surveys
conducted by PWMI.
・Incineration with power generation / incineration withheat utilization“Incineration with power generation” means incineration
processing by an incinerator equipped with powergeneration facilities and “incineration with heat utilization”
means incineration proce-ssing by an incinerator that,while not equipped with power-generation facilities, has
facilities for utilizing heat externally. The ratios shown aredetermined by PWMI surveys based on values publishedby the Ministry of the Environment. The announcement ofthese values, by the way, is now made at an earlier date by
the ministry, and this report therefore uses actual values
from the previous fiscal year .
3-4 Disposal and recovery of industrial waste
・Disposal and recovery of industrial waste is partiallycommissioned to local governments as business-related
waste. The ratio of such processing by business to thatcommissioned to local governments is determined on thebasis of PWMI surveys. The percentage breakdown ofcommissioned processing into incineration with power
generation, incineration with heat utilization facility,
incineration without power generation or heat utilization
facility, and landfilling is based on figures for domestic waste
processing.
The incineration/landfilling ratio in the processing ofindustrial waste and the energy recovery rate inincineration with power generation are based on the latest
surveys conducted by PWMI in fiscal years 2006/2008.

PWMI Newsletter 3

Flowchart of plastic products,
plastic waste and resource recovery
2012[ Unit; kt（thousand tons）]
Resin production, resin processing, and marketing of products

Discharge❶
Resinproduction

Resinexport10,5403,420
Resinimport2,470❷
Domestic
plastic products
consumption

9,600

Domestic Plastic
input

Use

9,370

Post-use
products
discharge

8,570

Note 3

Product
export800❸

pl

Product
import1,880
Liquidresin,etc.

910
Resin
processing
waste

550
Note 1Resinproduction
waste

Production
andProcessing
waste

Non-use

Production
andProcessing
waste discharge

720

170
Reclaimed
products

400

Note 2

Note 1: Resin production does not include the quantity shown for resin production waste
Note 2: The quantity shown this year for reclaimed products is based on that of mechanicalrecycling from the previous year (2,120 kt) excluding exported portion (1,630 kt) andthe amount used for fiber from PET bottles (100 kt).
Note 3: The figure for post-use products discharge is computed by a PWMI estimation system
based on usage for different demand areas and different resin types (from 1976) andproduct lifetimes for different demand areas (60-years discharge model created by
PWMI).
Note 4: Some figures may not exactly match due to rounding.
※ ❶〜❻ corresponds to the graph of next page.

4

720Disposal and recovery

Domestic waste
Mechanical recycling

680
Liquefaction, gasification, blast furnace

270❹

Densified-refuse derived fuelDomestic
waste

4,460

260

380
4%

Incineration without power generationor heat utilization facility

Densifiedrefuse
derived fuelLandfilling

1,070
12%

Industrial waste
Mechanical recycling

1,360
Liquefaction, gasification, blast furnace

110
Densified-refuse derived fuel810
Industrial
waste

4,820

2,040
22%

1,950

290

❺

recycling

Incineration withheat utilization facility

690

9,290

※6
❻MechanicalLiquefaction,
gasification,
blast furnace

Incineration with power generation

330

Total
lastic waste
discharge

Sum of waste

Incineration with power generation

1,070

Incineration
with power
generation

Incineration
with heatutilization facility

930
10%Incineration
without power
generation or heatutilization facility

960
10%
Landfilling

Incineration without power
generation or heat utilization facility

890
10%

270

7,440
80%

3,020
32%

Incineration withheat utilization facility

600

Utilized
plastic waste

Non-utilized
plastic waste

1,850
20%

Landfilling

600

PWMI Newsletter 5

Details of flowchart elements❶ Breakdown of resin production(10,540kt) by resin type

❷ Breakdown of resin products by field(9,600kt)
Others 510

Thermosetting
resin
940
Polyethylene
9.0%
2,600
Other
24.7%
thermoplastic
resin
2,100

19.9%

Thermoplastic
resin

Polystyrene
89.4%(including SAN, ABS)
1,170
11.1% Polyvinylchloride
1,330

5.3%

Agriculture,
forestry and fishery
170 1.7%

Householdarticles,etc.
880

9.2%

Containers andpackaging
4,110

Building materals
1,160

12.0%

Polypropylene
2,390Transportation
1,180

22.7%

12.3%

12.6%

42.8%

Electric andmachinery
1,600

16.7%

(Source: METI chemical-industry statistics)(Source: estimates from related organizations)❸ Breakdown of total plastic waste by field (9,290 kt)
Production andprocessing waste
720
Others
7.7%
550

Others
2,120

5.9%

22.9%
Building
materals
730 7.9%
Householdarticles,etc.
910

9.8%

Containers andpackaging
4,160

Post-use
products

44.8%

92.1%

Polyethylene
3,000

32.3%

Polyvinylchloride
820

8.9%

Polystyrene(including SAN, ABS) Polypropylene
2,160
1,180 12.7%

Electric andmachinery
1,570

23.3%

16.9%
Transportration
500 5.4%
Agriculture,forestry and fishery 150 1.7%
(by field)(by discharge type)❹ Breakdown of domestic waste by field(4,460 kt)
Agriculture,
forestry and fishery
0 0.1%

Transportration

0 0.0%

Householdarticles,etc. Production and
110
processing waste
2.2%
720

Others270

6.1%

Householdarticles,etc.
800

18.0%

❺ Breakdown of industrial waste by field(4,820 kt)

14.9%
Others270 5.7%

Containers andpackaging
3,090

Transportation
500

69.2%

Electric
and machinery
220 5.0%
Building materals 70

6

10.4%

Building
materals
660

13.6%

1.6%
(by resin type)

Electric andmachinery
1,350

28.0%

Container
and package
1,070

22.1%

Agriculture,
forestry and fishery 150

3.1%(by resin type)❻ Breakdown of mechanical recycling (2,040 kt)○ Breakdown of mechanical recycling resources

Production andprocessing waste
720 ktPET resin indesignated PET bottle
520

21.5%

25.5%

Post-use products
1,320 kt

35.3%

Polyethylene
440

64.7%

Polypropylene
390

19.0%

Others280(containing 680 kt ofpost-use products
from domestic waste)

13.8%

Polyvinylchloride
230

11.1%

Polystyrene(including SAN, ABS)
180 8.9%○ Breakdown of post-use products for mechanical recycling(1,320 kt)

500

PET bottles

240

Wrapping film

150

Home electric-appliancehousings, etc
Agricultural plastics

80

Expanded polystyrene
packing material, etc

70

Containers and the like

70
60

Electric-wirecovering material

40

Automobile parts

20

Pipes, etc.
Expandedpolystyrene trays

10

Non-PET bottles

1070

Others
0

10

20

30

40

(by type of reclaimed products)
Recycled products
260kt

12.9%

Recycled material
1,780kt

87.1%

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

500

[ thousand tons ]510(by destination of recycling use)
Domestic
280kt

13.7%

Export
1,670kt

82.1%
Fiber(from bottles) 80 4.1%

PWMI Newsletter 7

Plastics production and waste discharge
Year

Resin
production

Domestic plastic
products
consumption

Total plastic
waste
discharge

kt /yearkt /yearkt /yearDomestic waste

Industrial waste

kt /year%kt /year

%

1980

7,520

5,520

3,260

1,780

55

1,470

45

1985

9,230

6,990

4,190

2,320

55

1,870

45

1990

12,630

9,990

5,570

3,130

56

2,440

44

1995

14,030

9,790

8,840

4,430

50

4,410

50

1996

14,66010,810

9,090

4,550

50

4,540

50

1997

15,21011,360

9,490

4,780

50

4,710

50

1998

13,910

10,200

9,840

4,990

51

4,850

49

1999

14,57010,810

9,760

4,860

50

4,900

50

2000

14,74010,980

9,970

5,080

51

4,890

49

2001

13,88010,96010,160

5,280

52

4,890

48

2002

13,850

10,570

9,900

5,080

51

4,820

49

2003

13,98011,01010,010

5,130

51

4,880

49

2004

14,46011,360

10,130

5,190

51

4,940

49

2005

14,51011,59010,060

5,200

52

4,860

48

2006

14,450

11,20010,050

5,080

51

4,980

50

2007

14,65011,030

9,940

5,020

51

4,920

49

2008

13,45010,890

9,980

5,020

50

4,960

50

2009

11,210

8,430

9,120

4,440

49

4,680

51

2010

12,700

9,700

9,450

4,590

49

4,860

51

2011

11,590

9,870

9,520

4,650

49

4,860

51

2012

10,540

9,600

9,290

4,460

48

4,820

52
8

Change in Utilized Plastic Waste
by Amount and Rate Over Time
Year

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

10,1609,900

10,010

10,13010,06010,050

9,940

9,980

9,120

9,450

9,520

9,290

Utilization
amount
(kt)

5,130

5,160

5,410

5,750

5,820

6,880

6,920

7,330

6,890

7,230

7,440

7,440

Utilizationrate(%)

50

52

54

57

58

69

69

73

75

77

78

80

Total Plastic
waste
discharge(kt)

Please see the PWMI Web site for detailed data on the production, discharge, reuse, and disposal of plastic products.

100

12000

11000

10000

90

9000

8000

80

70

6000

5000
60

4000

3000

50

2000

1000
40

0
2000

2001

Machanical Recycle

2002

2003

2004

Feedstock Recycle

2005

2006

2007

Energy Recovery

2008
Incrinat

2009

2010

Landfilling

2011

2012

Utilization rate︵％︶utilization rate

︵ kt︶
Disposal and recovery

7000

Business Overview
History
Originally founded in December 1971 as
the Plastic Management Research
A s s o c i a t i o n , t h e P l a s t i c Wa s t eManagement Institute (PWMI) received
its current name in July of the following
year as operations expanded. For the last
40 years or so, PWMI has endeavored toresearch and develop technology for the
optimal processing and effective use ofplastic waste and to publicize its findings.
In addition, PWMI has changed into a
general incorporated association as a resultof Laws Related to the Reform of the
Public-Interest Corporations System(enacted in December 2008). As a resultof this change, PWMI’s objectives weren ew l y e s t a b l i s h e d i n A p r i l 2 0 1 3 a s“surveying and researching the recyclingof plastic waste and contributing to a
reduction in environmental load by the
total recycling of plastic, and helping
plastic-related industries to expand theirbusiness soundly and contributing to thecreation of a society capable of sustainablegrowth.”Business Content(1)Survey and research the generation,
recycling, and disposal of plastic waste
and promote the appropriate use of plastic
waste through various means including
techniques for evaluating environmental
load(2)Support the education and study of therecycling of plastic and plastic waste andengage in related public relations activities(3)Interface and collaborate with domestic
and foreign institutions in the plastic andplastic-waste industries

Activities
The three core activities of PWMI aresummarized below.
(1) Provision of life cycle assessment(LCA) base data and LCA evaluation ofrecycling technologies
PWMI provides scientific and highreliability data for widespread use byrelated industries and general citizens forapplication to carbon footprint systems,
etc. It also works to solve technical issues
so that the effective use of plastic waste
can be evaluated by LCA.
(2) Preparation of the Flowchart of Plastic
Products, Plastic Waste and Resource
Recovery and ongoing improvements to
its accuracy
PWMI strives to obtain a clear
understanding of the entire lifecycle ofplastic from its production stage to its
disposal and recycling and to prepare andprovide a highly accurate flowchart of thisprocess.
(3) Support of environmental education
PWMI continues to hold instructor
training courses and on-site classes andworks to raise the level of consciousness
in society regarding the usefulness ofplastic. In addition to holding on-siteclasses on plastic recycling at primary andmiddle schools especially in Japan’s Kanto
region, PWMI will honor as much as
possible requests for instructor training
courses in line with new teachingguidelines and for lectures at universities
specializing in environmental science.

April 2014 700

10Organization
General Meeting

Auditors

Board of Directors

Regular members: 17 corporations and 3
organizations
Supporting members: 3 organizations
Regular members
Asahikasei Chemicals Corporation
DuPont-Mitsui Polychemicals Co. Ltd.
Japan
Corporation
Auditors
GeneralPolyethylene
Meeting
Japan Polypropylene CorporationJNC Corporation
KanekaCorporation
Board of Directors
Maruzen Petrochemical Co., Ltd.
NUC Corporation
Steering Committee
Prime Polymer Co., Ltd.
Shin Dai-Ichi Vinyl Corporation
Shin-Etsu Chemical Co.,Committee
Ltd. onGeneral Affairs
Sumitomo Chemical Co., Ltd.
SunAllomer Ltd.
Committee on Surveys
Taiyo Vinyl Corporation and Research
Tosoh Corp.
Committee
on Public
Tokuyama Sekisui Co.,Ltd.
Relations andEducational
SupportUbe-Maruzen Polyethylene Co.,
Ltd.

Chai

Vice-Ch

Steering Committee

Executiv

Committee on
General Affairs

Members (as of January 2014)

Plastic Waste Management InstituteWeb site: http://www.pwmi.or.jp

Trade organizations
Japan Petrochemical Industry Association
Japan Plastics Industry Federation
Vinyl Environmental Council
Supporting members
Japan PET Bottle Association
Japan Expanded Polystyrene Recycling
Association
Japan PVC Environmental Affairs Council
Directors
Chairman: Hiroaki Ishizuka
Vice-Chairman: Shunzo Mori
Executive Director: Hisao Ida
Directors: 10
Auditors: 2

SecretarCommittee on Surveys
and ResearchCommittee on Public
Relations andEducational Support

Chairman

Advisors

Vice-Chairman

Executive Director

Secretary General
General Affairs and Public
Relations Department
Surveys and Research
Department

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Tel: 81-3-6855-9175~7, Fax: 81-3-5643-8447