Recycling Meets Innovation: Nova’s Alan Schrob on the Future of Flexible Packaging

ChemAnalyst Talks with Mr. Alan Schrob, Director of Mechanical Recycling, Nova Chemicals

NOVA Chemicals, a global leader in polyethylene solutions, is redefining the future of sustainable plastics through a strategic combination of innovation, circularity, and collaboration. The company is transforming how the plastics industry designs, produces, and recycles materials, advancing ambitious sustainability goals while partnering with organizations such as Charter Next Generation (CNG) to expand the use of recycled polyethylene (rPE) in flexible packaging. ChemAnalyst spoke with Alan Schrob, Director of Mechanical Recycling at NOVA Chemicals, about his professional journey, the technical and commercial case for rPE, and the company’s broader commitment to enabling a circular economy, reducing greenhouse gas emissions, and setting new industry standards for high-quality, recyclable plastics.

Complete Interview with Alan Schrob

Please provide an overview of NOVA Chemicals’ partnership with Charter Next Generation (CNG) to commercialize rPE in flexible packaging and explain how it aligns with long-term sustainability goals.

Alan Schrob : NOVA Chemicals and CNG have enjoyed a long-time highly collaborative supplier and customer relationship. This announcement is yet another example where NOVA Chemicals and CNG have developed a partnership to advance the use of recycled polyethylene (rPE) in flexible packaging applications. In this long-term supply agreement, CNG will utilize SYNDIGO™ rPE resin to support CNG’s GreenArrow™ product portfolio. End use applications include cereal bags, shrink film, and overwrap for household paper products. The partnership leverages NOVA’s new Connersville, Indiana, recycling facility, known as SYNDIGO1, and CNG’s Midwest operations in Wisconsin and Ohio to strengthen regional supply chains. Together, we are combining resin innovation with manufacturing expertise to build end-markets for post-consumer recycled (PCR) content and lower greenhouse gas emissions.

What technical processes and quality control measures ensure that SYNDIGO rPE consistently meets the requirements of flexible packaging applications?

Alan Schrob: For rPE production, quality control begins with careful sourcing and chain of custody tracking of incoming film bales. Chain of custody documentation is critical for producing food-contact compliant resins and obtaining a Letter of Non-Objection (LNO) from the U.S. FDA. The incoming material is sorted using state-of-the-art optical sorters that separate PE films from other plastics and contaminants. Cross contamination is prevented with separate wash lines and silo systems. Any plastic unsuitable for food contact applications is diverted to alternative applications such as plastic lumber. The PE film is then shredded, thoroughly washed to remove adhesives and surface contamination, and dried before extrusion into pellets. The resin is circulated in hot air to eliminate residual tastes and odors. Finally, the pellets are blended in silos to ensure a uniform, high-quality resin suitable for flexible packaging performance and consistency.

We also leverage our steep experience in high-performing virgin PE resin production by applying the same equipment and testing at SYNDIGO1. For more advanced prototypes and analytics, we can send SYNDIGO resins to our laboratory facilities in Calgary, AB, Canada.

Since SYNDIGO1 became operational, how has the facility performed in terms of production ramp-up, customer reception, and meeting initial operational or commercial targets?

Alan Schrob: We are very pleased with the completed construction at SYNDIGO1. The facility is generally ahead of schedule, and we have made significant progress in commissioning the lines. Prime production has begun on the intended products that we have sampled for our customers, and we are ramping up production and building inventory to ensure we can support commercialization of SYNDIGO products in our customers’ applications.

In the evolving recycled plastics market, where are the most promising growth opportunities emerging, particularly for flexible packaging applications?

Alan Schrob: Food contact flexible packaging has significant growth potential for PCR plastic. While supplies of high-quality PCR materials still currently fall short of demand, emerging Extended Producer Responsibility (EPR) legislation will drive the expansion of recycling collection and processing infrastructure. PCR content and recyclability mandates will also reshape design approaches for food packaging, which relies heavily on flexible packaging formats such as bags and pouches.

How are regulatory changes—such as U.S. tariffs, EU import rules, and India’s recycled content mandate—shaping global trade flows and influencing NOVA Chemicals’ strategy?

Alan Schrob: While we follow all of these factors very closely, our raw material sources are located in the United States and the finished products made at SYDNIGO1 are destined for our customers within North America. 

With Middle Eastern producers investing in recycling infrastructure, how might this affect global supply dynamics for recycled polyethylene, and what are the implications for sourcing and competitiveness?

Alan Schrob: Mechanical recycling is very much a “local business” in that raw materials for flexible mechanical recycling are expensive to source over very long distances, especially from other regions of the world. Additionally, regulations for the use of recycled materials are different in each country. We are very confident in our ability to supply the highest quality rPE resins competitively in North America.

Several global players have introduced their own recycled polyethylene solutions. In what ways does SYNDIGO rPE differentiate in terms of quality, performance, and scalability, and how does the partnership with CNG strengthen its market position?

Alan Schrob: NOVA Chemicals goes beyond the LNO to leverage decades of experience in resin production, product stewardship, and regulatory requirements to develop rPE products that meet market needs. While many recycled plastics are downcycled into lower-value products, SYNDIGO rPE resins are supplied into a host of demanding applications, including food-contact packaging. Packaging films from retail and distribution centers represent an underutilized source of high-quality plastic that can be used to create closed loop systems for flexible packaging. NOVA Chemicals is also unique in its capability to help brand owners and retailers design and implement film collection programs to overcome barriers in sourcing and transporting PCR films.

Our partnership with CNG enhances market impact by combining NOVA Chemicals’ expertise in producing rPE with CNG’s flexible packaging capabilities. This collaboration will help expand the adoption of PCR content across the industry, enabling new applications, supporting a circular supply chain, and strengthening SYNDIGO rPE’s position as a reliable, high-performance solution for brand owners and converters.

What methodology is used to measure the emissions reduction benefits of SYNDIGO rPE compared to virgin polyethylene, particularly in flexible packaging life cycles?

Alan Schrob: Mechanical recycling benefits from well-established core technology that continues to expand and become more efficient. The mechanical recycling process for PE requires lower energy use and resource consumption than virgin resin production, resulting in a carbon footprint that is far less the carbon footprint of virgin PE.

How does the collaboration between NOVA Chemicals and CNG improve supply chain resilience and provide value to companies seeking to increase recycled content without compromising performance?

Alan Schrob: Long-term supply agreements like the partnership between NOVA Chemicals and CNG promote the development of film recycling infrastructure. When manufacturers integrate PCR materials into their product lines, recyclers benefit from reliable demand and greater financial security to invest in operational improvements. In addition, the Midwest regional supply chain has many sources of back-of-house films from major metropolitan areas including Indianapolis, Columbus, Ohio, and Chicago, ensuring consistent, high-quality supply of PCR feedstock. 

NOVA Chemicals’ expertise in resin formulation, combined with CNG’s manufacturing capabilities, will demonstrate the ability of rPE to meet the rigorous requirements of flexible packaging applications. The partnership shows brands and converters that rPE can be successfully integrated into high value applications, supporting circularity goals while maintaining product quality, durability, and performance, and streamlining development for future end uses of rPE.

Looking toward 2035, what role is envisioned for NOVA Chemicals and CNG in shaping the global rPE market, and how will success for this partnership be defined?

NOVA Chemicals and CNG are committed to demonstrating that recycled films can be an economically viable, scalable solution for PCR flexible packaging. By leveraging SYNDIGO1 in Connersville, the goal is to divert plastic films from landfills and keep them in circulation in valuable applications. The collaboration will contribute to a circular economy for plastics, deliver rPE solutions to customers, and set industry benchmarks for PCR plastic quality, performance, and scalability.

We continue to see increasing interest in rPE from brand owners, converters, and retailers. CNG is part of our growing network of manufacturers and distributors that are working toward incorporating rPE in flexible packaging.

Alan Schrob is director of mechanical recycling at NOVA Chemicals. He spent 20 of his 30 years in the plastics industry encouraging circularity in a variety of roles, including business development, marketing and the rigid and performance films markets.

ChemAnalyst Insights on Recycled-High Density Polyethylene (R-HDPE)

In Europe, the R-HDPE market experienced a modest decline through the second quarter of 2025. In Germany, the spot price trended downward amid soft demand and increased imports. While prices remained stable in April, May saw a dip in demand as macroeconomic challenges and reduced restocking by rigid packaging companies affected the market. This trend continued into June, with prices falling slightly due to weakened downstream confidence and high inventory levels. Although production costs for R-HDPE stayed relatively flat, recyclers faced margin pressures as downstream converters negotiated lower prices. Overall demand during the quarter was subdued, particularly in the packaging and automotive sectors, while a surge of imported recycled granules from Eastern Europe added further pressure on pricing.

In July 2025, R-HDPE prices in Europe remained stable, with the price index unchanged. Most buyers maintained short-term orders, and recyclers adjusted their operations cautiously in response. Looking ahead to the third quarter, the R-HDPE price forecast suggests a slight rebound, supported by regulatory-driven purchases and gradually recovering export interest.