• Renewal process

    Constant innovation is aiding the paper and forestry industry to transform recycling

    Renewal process

    As the push to implement circular-economy principles gains momentum worldwide, in South Africa, innovative approaches are emerging to transform waste management, resource utilisation and sustainable development, despite challenges.

    Paper and pulp forestry is arguably at the forefront of this transformative approach, thanks to high recycling rates, carbon sequestration and the sustainable harvesting of timber, as well as ongoing investment in technological innovation. However, this sector’s potential for continued innovation and growth has been significantly dented by escalating electricity, ports and rail infrastructure crises.

    According to Forestry SA – which represents 93% of the country’s forestry industry – operational inefficiencies have resulted in rail transport halving from a peak of 3.5 million tons per annum in 2005 to 1.7 million tons in 2022, leading to increased reliance on transportation on overburdened roads (more costly both economically and in carbon emissions).

    In April 2023, Forestry SA met with President Cyril Ramaphosa and relevant ministers to present recommendations for the urgent remedy of the ports and rail crisis. While load shedding seems to have been resolved, Transnet now faces a credit downgrade by ratings agency S&P thanks to ballooning debt – yet Forestry SA’s Ronald Heath is optimistic. ‘We are happy to say we have seen significant improvements that emanated from the [April 2023] meeting – not only for our sector, but for the country as a whole,’ says Heath. ‘From that meeting, we saw the president establish two critical structures – the National Electricity Crisis committee and the National Logistics Crisis committee. These structures comprise government and private-sector representatives as well as subject matter experts. They have created a platform for government and the private sector to collectively address both the electricity and logistics and infrastructure challenges the country faces. On the electricity front, we have been load shedding-free for more that 250 days.’

    In the logistics space, Heath adds, there have been noteworthy improvements in rail, ports and road. ‘In contrast to the past, we now see government and the private sector working together to repair damaged roads, damaged infrastructure at our ports, and paving the way forward to improve our rail networks through innovative initiatives that will be captured in the Network Statement being developed collectively by government and the private sector. In addition, our sector has also seen improved service delivery on rail and at our ports, directly adding to our competitiveness.’

    The industry sustained additional challenges, such as unprecedented tree mortality due to extreme weather conditions, coupled with depressed global markets. Yet it remains remarkably resilient. From 2019 to date, it has invested more than ZAR33.2 billion, 27% higher than it committed to the Public Private Growth initiative (aimed at supporting rapid growth in the country’s economy) back in 2019. ‘To add to this, just recently, a number of our members signalled a planned additional ZAR11 billion investment over the next three years,’ says Heath.

    At the end-point of the circularity scale, South Africa’s paper recycling rates are in line with global averages (roughly 50% to 60%), and are aligning with more developed regions. In 2023, South Africa’s recycling rate was 63.5% (with a five-year average of 65.3%), compared with approximately 70% in the US, and 79% in Europe.

    While industry investment in recycling infrastructure and a high recovery rate have helped it to grow, a number of challenges remain. Unlike Europe, where separation at source is regulated – for example, citizens and companies may be fined if they neglect to separate their recyclables from other refuse – South Africa has no such system in place and relies largely on collection companies and informal waste collectors. This means that a certain amount of recyclable paper waste is lost to, for example, landfill or to contact with refuse that renders it unrecyclable.

    Another challenge is widespread application of European recyclability standards. Currently, most recyclability standards applied in South Africa are based on European methodologies, which can in some cases lead to products being perceived as sustainable and recyclable when this is not the case locally.

    In an industry first, South Africa’s producer responsibility organisation for paper and packaging, Fibre Circle, has launched an initiative to develop a recyclability standard and labelling system tailored to South Africa.

    ‘European standards are designed for markets with infrastructure, recycling technologies, and consumer behaviour that differ from those of South Africa,’ says Fibre Circle CEO Edith Leeuta. ‘In South Africa, where we have a blend of formal and informal recycling systems, labelling systems and recyclability definitions based on European standards may fail to consider the realities of our waste streams and local end-use markets, potentially misleading consumers – greenwashing – and producers, and limiting economic opportunities for recyclers.’

    The plan is to complete all consultation and testing for the new standard by the end of July 2025, following which, drafting will begin in September 2025, with the standard being made available for public comment in October 2025. A final version as an industry-adopted standard is planned to be available by the end of November 2025, whereafter the process will begin for submission and acceptance as a national standard.

    The past year has already seen several other developments in paper recycling, according to Leeuta. ‘2024 has been a year of considerable change, with the establishment of a local recyclability testing facility for paper and paper packaging, reducing costs and lowering the barriers to testing overseas.’ In addition, trials and a pilot project for recycling label-backing paper into tissue products achieved commercial success, establishing a commercial value or rebate for the material and driving demand for its collection and diversion from landfills.

    Research into difficult-to-recycle materials, such as potato sacks, also commenced in 2024. ‘The work has already assisted in the redesigning of potato sack materials to better align with the local recycling industry, and continued work may soon see these types of packaging materials being recycled with packaging papers,’ says Leeuta.

    ‘We have also seen the roll-out of reverse vending machines, where consumers can earn points or coupons at selected Pick n Pay stores, as well as plans to roll out these machines at universities. These machines can greatly assist in the recycling of liquid board packaging [cartons for packaging of liquids], by incentivising the return of materials.’

    The paper and pulp forestry industry is a leading player in the circular economy, which is driven by high recycling rates, sustainable timber harvesting and continuous investment in technological innovation

    Further developments have been announced by the Paper Manufacturers Association of South Africa (PAMSA), in collaboration with Stellenbosch University, Sappi Southern Africa and Mpact – a solution to convert cellulose fibre-rich waste from pulp and paper mill operations into ethanol using a specialised fermentation process. Ethanol is used in the production of industrial chemicals, bio-based plastics and sustainable aviation fuel.

    ‘This technology started as a research project and thesis by one of our masters in engineering students, and today we have a South African first,’ says Jane Molony, PAMSA executive director. ‘Bioethanol comes with many environmental credentials and further contributes to the circularity of the pulp and paper sector.’ Ultimately, this solution will help to reduce the amount of waste disposed to landfill and the associated greenhouse gas emissions and improve water reclamation for re-use, further contributing to the circular economic and industrial decarbonisation, claims PAMSA.

    It’s clear that the future of circularity in the paper and pulp forestry sector in South Africa holds immense promise as innovation continues to redefine the industry’s potential. With growing investments in recycling infrastructure, tailored local standards, and groundbreaking technologies such as bioethanol production, the sector is poised to play a pivotal role in advancing sustainable development across the continent.

    By Robyn Maclarty
    Images: Unsplash, Freepik