Smarter Sorting Puts Europe’s Bio-Plastics to the Test

EU-backed PROSPER initiative upgrades existing recycling lines to improve identification of bio-based plastics

17 Dec 2025

Europe’s plastics industry is testing whether artificial intelligence can help resolve a growing mismatch between the design of bio-based plastics and the ability of recycling systems to handle them at scale.

An EU-backed initiative known as PROSPER is seeking to improve the identification and separation of bio-based plastics within mixed waste streams, using AI to enhance existing near-infrared and optical sorting equipment rather than replacing it. The approach is intended to address persistent problems of misidentification and contamination that have limited the commercial viability of recycling newer plastic materials.

Bio-based plastics are no longer confined to pilot projects, particularly in packaging. But recycling systems have struggled to distinguish them reliably from conventional polymers once they enter municipal waste flows. Incorrect sorting can lead to downgraded recycled output, reducing quality and weakening confidence among buyers.

The PROSPER project adds an AI layer that analyses sensor data in real time, refining decisions already made on the sorting line. Project partners say this allows operators to adapt to complex and variable waste streams without major changes to infrastructure.

Early pilot trials have produced encouraging results. Bio-based plastics were deliberately introduced into municipal packaging waste and processed in working recycling facilities rather than laboratory settings. Under these conditions, the system was able to identify and separate the materials with a level of accuracy that suggests it could be deployed at scale.

Improved sorting has direct economic implications. Contamination remains one of the main cost drivers in plastics recycling, as even small errors can lower the value of recycled material. More reliable identification could make bio-based plastics a predictable input rather than a source of risk for recyclers.

The initiative comes as regulatory pressure across Europe increases. Packaging rules are tightening, recycled content targets are rising and environmental claims are facing greater scrutiny. More accurate sorting could help recyclers meet these requirements while giving brands greater confidence in supply and compliance.

PROSPER also reflects a broader shift towards digital tools in waste management, as operators invest in AI and data systems to improve efficiency. While challenges remain, including ongoing system training and investment needs, the project highlights how incremental technological upgrades may help close the gap between sustainable design and real-world recycling performance.