Plastics in Practice

Plastics have become indispensable in many sectors: packaging, transport, medicine, the home, construction and much more. In this section, you will find numerous articles on the use of plastics in various contexts.

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Results (111)

  • Fish in packaging made from chemically recycled plastic

    Source: Peter Tubaas, Vestland Media 07.03.2022 Contaminated or mixed plastic waste poses a problem for the circular economy – it can't be recycled and ends up in dumps or in a thermal recycling process. BASF has now developed styropor boxes made from chemically recycled plastic in a joint project with Vartdal Plast and Bremnes Seashore. Perfectly cooled, securely packaged: The styropor boxes which are made from chemically recycled plastic have the tried-and-tested properties of normal styropor and a lower CO2 footprint. Source: Peter Tubaas, Vestland Media In Norway, Bömlo’s salmon fillets have been being delivered in primary packaging made from chemically recycled plastic since Christmas. This material has been named Ccycled, and is made from expandable polystyrene (EPS) which is particularly suited to use in passive cooling systems. New fossil resources are no longer needed, as Ccyled is made from pyrolysis oil which is obtained from a thermochemical process called pyrolysis. In 2014, a uniform name was created for styropor: airpop. This name has since become a byword for styropor. Together, the three companies have found a way to operate a circular economy for plastics that are usually difficult to recycle or even unrecyclable. Technology partners supply BASF with pyrolysis oil for this, which is converted into EPS granulate. Vartdal Plast then manufactures the styropor boxes for fish from this granulate. Simon Nesse Økland, Head of Development at Bremnes Seashore, explains how this is particularly advantageous for transporting food: "The fish box made from EPS has been an optimal solution for us for quite a while now, as we can ensure compliance with the cold chain during transportation thanks to the amazing properties of this material. An unbroken cool chain is crucial for food safety and preventing food waste. Here at Bremnes Seashore, we have been won over by the opportunity to test this alternative which has a far lower CO2 footprint than other options, and we place great value on any initiative that promotes a circular economy." Naturally, a styropor box made from chemically recycled plastic needs to prove itself, particularly as compared to conventional boxes. Here, Ccyled wins over clients thanks to its great thermal insulation, and in addition to this, the boxes are resistant to compression, bending and can be stacked stably. The recycled styropor thus has the same properties as the conventional alternatives. The ecological balance sheet also looks good: the recycled airpop version reduces CO2 by at least 50 percent. "Chemical recycling of plastic waste is not only an important component of the European circular economy, it is also particularly useful for applications which have stringent requirements in terms of quality and safety, for example food packaging and protective packaging or pharmaceutical boxes. Therefore, we are very proud of the ChemCycling project and to manufacture EPS fish boxes for Bremnes Seashore. We are delighted that we can thus help our customers to achieve their sustainability goals," explains Klaus Ries, Head of Global Business Management for Styrenic Foams at BASF. A further benefit: Vartdal Plast benefits from the fact that the material can be processed like new material, meaning that the production processes do not need to change. At BASF, recycled and fossil raw materials are mixed in the production Verbund and the proportion of recycled matter is calculated and allocated via a mass balance. Both the process of allocation and the product are certified by an independent testing authority. Styropor has been a well-known material for 70 years, and is particularly popular in passive cooling systems. Therefore, the boxes are gaining ground both in the pharmaceutical industry and the food industry. The world's first EPS fish boxes are in use in Norway thanks to Ccyled. The standard box from Vartdal Plast, which weighs just 600 grams, can hold around 22 kilograms of fish. For Vartdal Plast, the new boxes are particularly amazing because they are recyclable. In Scandinavia and other European countries, the boxes are collected, compressed, crushed and recycled. The company operates two high-capacity compacting plants for EPS waste in Norway. In the long term, Vartdal Plast is looking to feed the compacted material back into their Vartdal Loop product series and thus manufacture boxes that are made entirely from recycled styropor. Source tightly packed - interpack magazin More around Packaging

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  • Mobile plastics recycling project wins WDO's World Design Impact Prize

    Upcycling technology by Taiwan's Miniwiz turns waste into architectural tiles This modular miniTrashpresso system was set up in Sardinia, Italy. Courtesy of Miniwiz 30.03.2022 The Montreal-based World Design Organization has named a mobile, solar-powered, plastic-waste upcycling platform as the winner of its World Design Impact Prize™ for 2021. Designed by Taiwanese engineering firm Miniwiz Co. Ltd., the system – called Trashpresso – is said to be "the world's first mobile waste recycling plant that transforms industrial and household trash into sustainable materials." After WDO issued an open call for nominations, a review panel of international experts shortlisted the entries to 10 projects. The design group’s international membership voted to determine the three finalists which, in addition to Trashpresso , included a Dutch self-cleaning water filter called JERRY: The Jerrycan Waterfilter , and a personal safety app from India called My Safetipin . WDO membership then selected the winner late last year. Miniwiz has dubbed its second-generation Trashpresso system "miniTrashpresso," highlighting that it is more compact, energy-efficient and portable than the first iteration. Courtesy of Miniwiz First developed in 2017, Trashpresso consists of a 40-foot container housing the processing line and a 20-foot solar cell unit. Both units are said to be "land, sea and air transportation ready." Miniwiz, founded in March 2005 by architect and structural engineers Arthur Huang and Jarvis Liu, continues to work to make Trashpresso more compact and intelligent. Trashpresso compacts the recycling process into three steps: size reduction, purification, and reshaping. Additionally, the firm says air and water filters further safeguard the environment against discharge from the processing operations. Trashpresso can process various types of plastic, including polystyrene, expanded PS foam, polypropylene, PET, and low density and high density polyethylene, and products such as bottles, caps, plastic cutlery, cup lids, marine rope, bubble wrap, bags, razors, syringes, gloves and more. Its most visible end product to date are these molded architectural tiles. Courtesy of Miniwiz The system is capable of handling 50 kilogram of waste plastic per hour. It processes that waste into robust, low-cost, architectural tiles that can be used for interior or exterior decoration, flooring or insulation. Miniwiz says it takes five plastic bottles or about 50 caps and ringlets to produce one tile. The system cannot yet handle thin films such as bottle labels. The Miniwiz website also shows other possible end-use applications, such as bowls, drink coasters and personal accessories. Two Trashpresso lines are currently running – one in Asia and one in Europe, with more sites planned. The company says its R&D team is developing new portable recycling lines that can operate independently or as part of a closed-loop system. It notes that Trashpresso 3 is under development at the Miniwiz labs in Taiwan and Germany, with the aim of introducing the line to North America. It suggests that containers will no longer be needed and that only two simple truck trailers will be needed to transport the units in the future. Additionally, the solar panels will be flexible. Miniwiz exhibits at trade shows and organizes demonstration events – such as this one in Singapore – to help educate the public about its ability to turn plastic trash into useful, upcycled products. Courtesy of Miniwiz When announcing the design prize winner, WDO stated: "With the ultimate goal of incentivizing upcycling for both developed and developing communities around the world, the project showcases the need to strengthen and innovate existing waste management systems and boost engagement and awareness for sustainable practices." WDO created the World Design Impact Prize in 2011 "to honor and elevate industrial design driven projects that use design and/or design thinking to make a positive impact on our social, economic, cultural and/ or environmental quality of life." It gives out the honor every two years. More information about the equipment used and the processing line here. More around Materials Design

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  • WorldStar Award 2022 for school milk packaging made from 100% rPET

    Source: PantherMedia / akiyoko51 24.03.2022 New year, new accolade: The World Packaging Organisation has announced the winners of the WorldStar Awards 2022. Among them was a joint project between Austria's school milk producers and three Upper Austrian companies (PET-MAN, Greiner Packaging, and Starlinger viscotec), which involved producing sustainable cups from 100% recycled PET (rPET) to be filled with school milk for the state of Upper Austria. The Sustainably Packaged School Milk Project – a joint effort between Austria's school milk producers and Upper Austrian companies PET-MAN, Starlinger viscotec, and Greiner Packaging – won a WorldStar Award in 2022. Source: rPET cup Sustainability and a closed loop for plastics are front and center as we move into the new year. Since last spring, used school milk cups made from PET have been collected separately so that they could be recycled in a dedicated closed loop. And shortly before Christmas, this loop was closed for the first time. Used school milk cups collected before the fall were shredded, washed, recycled, and new rPET cups were made from the material. The first crates containing freshly recycled rPET cups have already been delivered to the school milk producers. The flagship project proves that a circular economy is possible in the plastics and packaging industries. And the solution has now received a WorldStar Award 2022 in light of this accomplishment. The awards have been running since 1970 and are highly coveted, with 440 submissions from 37 countries around the world vying for the World Packaging Organisation's stamp of approval. After picking up a TRIGOS and a Green Packaging Star Award in 2021, the project partners are proud to have their work recognized a third time with the WorldStar Award 2022. "It really is great to see our efforts receive this level of acknowledgment. For us, sustainability is not just a catchphrase – it is a duty we take very seriously. Thanks to the project, as well as doing our part to advance sustainability in general, children can be taught to treat nature responsibly from a young age," says Manfred Stanek, CEO of Greiner Packaging. Johannes Strobl, who represents the Upper Austrian school milk producers, is also delighted: "The feedback I have received from the school milk producers is that the schools are excited about the project. They appreciate the fact that the used rPET cups really are made into new cups." Starlinger viscotec is also convinced that rPET is the ideal choice for food packaging: "Our vision is to have a process in place for collecting and recycling packaging made from white rPET," says Herbert Hofbauer. "After all, used cups are a valuable material." Since March 2021, school milk farmers in Upper Austria have been filling their milk products in recyclable cups made from recycled PET. Source: rPET cup The concept behind the sustainable packaging sounds simple enough, yet it is a unique proposition. Austria's school milk producers supply schools and kindergartens directly with dairy products in rPET cups. The children consume the drinks during recess, then the used cups are gathered and returned for recycling to the school milk producers. Once collected, these cups are picked up from the farm, washed, and shredded. The resulting flakes are then cleaned and processed. As was the case for the first time before Christmas, the extruded rPET sheet is subsequently used at Greiner Packaging to thermoform new rPET cups, which are then refilled by the farmers and delivered once again to schools and kindergartens. This closed loop releases over 30% less CO2 than reusable glass bottles, which are significantly heavier. Recycling the cups also requires less energy than processing reusable glassware, for instance, and produces less waste. The reason the cups can be recycled so easily is that they are unprinted and made from 100% monomaterial. The recycling loop for rPET makes it a material with a promising future. And as things stand, recycled PET is the only post-consumer secondary plastic approved for food applications in the EU. The white rPET packaging can be reprocessed into food packaging, making it the ideal recyclable packaging solution for dairy products. Source rPET cup More around Packaging

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  • Track and trace system as an answer to encourage reusable packaging

    Source: PantherMedia / Andriy Popov 06.12.2021 The digital economy can help us prevent packaging waste, say researchers at Lancaster University and University of St Andrews, who are working with the founders of Reath, a start-up business based in Edinburgh, with a mission to build the digital infrastructure for reuse. The research findings are based on interviews with manufacturing brands, retailers, regulatory bodies, NGOs and reuse experts from industries, including food and beverage, cosmetics, and household products, to determine businesses’ reasons for not investing in reusable packaging. The research team also asked how digitalisation might help overcome these challenges. The interviews were used to create the world’s first 'Open Data Standard' for reusable packaging – an agreed vocabulary for data collection that helps organisations work together as a container moves between the manufacturer, transport provider, retailer, customer, and cleaning provider. Lead author Dr Katherine Ellsworth-Krebs, of Lancaster University's ImaginationLancaster laboratory, says: "Discussing what data is needed for reuse revealed how digitalisation supports collaboration, identifying points of miscommunication between key actors along the value chain." Exhibitors and products around science and research: Science and consulting Professional literature Trade associations Subcontracting "Collaboration is essential for the circular economy because one company cannot close the loop alone, it requires the whole ecosystem to work together." Four big business concerns identified: Questions of affordability due to additional expenses from changing their systems Concerns about increased risks and complications for health and safety The potential to hurt brand reputation if their scheme didn't turn out to be better for the environmentCurrent regulations that make single-use containers more competitive. Because packaging taxes are based on weight, business investing in reusable packaging are actually penalised because improving durability often results in heavier containers Traceability, via digitalisation, is a necessary step to launch and scale reusable packaging systems. Source: Lancaster University The study says digital trackers, unique barcodes, can address these hurdles. Being able to track an individual container enables businesses to calculate packaging lifespans and return rates from customers. Both are crucial to determining affordability. The unique barcode on a container is needed for recalling batches and evidencing cleaning between refills and return to the shop floor. These 'digital passports' also enable businesses to tell packaging stories in an appealing way, as they are able to verify and quantify their reuse activities for marketing purposes. A reusable container may require many uses for its environmental footprint to compare favourably with single-use alternatives, and so accurate accounting for refills is core to useful life cycle assessments. Currently organisations pay environmental taxes when packaging is released onto the market, but with digital trackers, it would be possible, to exempt organisations from paying every time their packaging is re-filled. In this way, track and trace allows governments to create taxation that incentivises reuse. "Being able to tag and track packaging through digital passports has long been hailed as a cornerstone of resource efficiency because it allows for monitoring of reuse," adds Dr Ellsworth-Krebs. "There are currently no government targets for reuse of packaging in the UK or EU due to this monitoring challenge. Advances in digital technologies open up new possibilities for a cooperative circular economy, including stopping packaging becoming waste soon after it leaves the shop floor." Reference Katherine Ellsworth-Krebs , Claire Rampen , Emily Rogers , Lauren Dudley, Lucy Wishart : " Circular economy infrastructure: Why we need track and trace for reusable packaging " Source Lancaster University More around Packaging

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  • New cutting-edge thermoplastic materials for the aerospace sector

    Results from the European HITCOMP project Source: Rawpixel 23.05.2022 The Universidad Carlos III de Madrid (UC3M) coordinates the HITCOMP (High Temperature Characterisation and Modelling of Thermoplastic Composites) project within the Horizon 2020 programme, which aims to study the possible advantages of thermoplastic materials in the aerospace industry. New cutting-edge thermoplastic materials for the aerospace sector. Copyright: UC3M The European aerospace sector typically uses low-weight, high-performance thermosetting plastic composites—also known as epoxy resin based composites—in many applications. However, these materials are not as heat resistant as other metal aircraft components, which can compromise safety in situations where extreme temperatures are reached. In an effort to improve the current thermosetting composites' behaviour in the face of heat damage, the HITCOMP research team has proposed an alternative: the use of new PAEK resins-based thermoplastic materials. During the development of the HITCOMP project, components made from a thermoplastic base have been shown to be more efficient, from the perspective of their thermal properties, than thermosetting composites. A known property that makes them very useful is that they can be recast, reshaped, processed and recycled, without the need for any additional curing process in order to harden and set. In addition, they are more versatile, cheaper and eco-friendly materials than conventional thermosetting composites and have a longer service life, thanks to their high resilience —they can be recycled or repaired more easily— and fatigue resistance —wear and tear— and corrosion. The introduction of these materials would mean having safer and lighter aircraft which consume less fuel, improve energy efficiency and reduce their emissions. To get the most out of thermoplastics in the aerospace industry, due to their capacity to melt and deform when overheated, it is necessary to determine their behaviour when subjected to heat, fire and mechanical loads. The HITCOMP project has developed a test laboratory with new infrared (IR) thermography techniques in order to obtain accurate and non-intrusive measurements of the actual temperature of materials during fire tests. The ultimate aim is to conduct virtual tests on thermoplastics and compare their performance in real applications with those of conventional thermosetting composites. "The aerospace sector is undergoing a transition to a more electric aircraft. This involves more heat and eventually fire sources, increasing the heating effect on the structure", explains Fernando López, lead researcher and coordinator of the HITCOMP project, from the UC3M Department of Physics. "In this context, our project aims to establish an innovative methodology which allows a characterisation of thermoplastics that involves fewer resources and improves the prediction of their behaviour and resistance when subjected to mechanical loads or fire and high temperatures." The measurements obtained by infrared thermography allow computer simulations to be carried out, which virtualize testing to select this type of material in the aeronautical industry. Its implementation is expected to "significantly reduce the number of validation tests, which are mandatory and greatly increase the cost and delay the approval of this type of material in the industry." The IR models and equipment have already been transferred to the Airbus company so that it can study their industrial application.During the research process, the team has also developed a new method —inspired by the previous results of UC3M's Sensors, Remote Detection and Infrared Imaging Laboratory (LIR-InfraRed LAB)— which allows the use of these infrared imaging techniques to remotely determine the thermal properties of these materials, without contact. Source Universidad Carlos III de Madrid More around Mobility

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  • SK chemicals realizes good takeout with Dodori Cup made from Ecozen

    Finally, people are drinking coffee in reusable cups in Ulsan Copyright: svitlanah 21.06.2022 SK chemicals (CEO Jeon Kwang-hyun) announced on May 6 that the company would start the Reusable Cup Project in partnership with Ulsan Broadcasting Corporation (UBC). The reusable cup recovery model, which means paying a deposit to rent a cup, and returning it after use, started in Freiburg, nicknamed Germany's environmental capital in 2016, to reduce environmental pollution by limiting the use of plastics. A cafe drink in Dodori cup made from SK chemicals' Ecozen. Source: SK chemicals SK chemicals is planning to reduce the use of plastics and protect the environment by making takeout cups with ECOZEN so that they can be used multiple times unlike disposable plastics that are used once and discarded. 5,000 Dodori cups used in this project are made from Ecozen. Ecozen uses plant-derived ingredients with superior heat resistance, contamination resistance to undiluted solutions like coffee, oranges and lemons, and chemical resistance compared to existing copolyester SKYGREEN products. Also, since there is no concern of exposure to bisphenol A (BPA) and phthalate plasticizers, classified as environmental hormones, the material complies with all requirements for food contact materials at home and abroad. ECOZEN is ideal for use in electronic products, food containers, and baby products. The Dodori cup made from Ecozen contains the hope that it will come back like the repeat sign (dodoripyo) in music, benefit the environment and our lives, and that the resource circulation will continue happily like a sing-along. UBC, SK chemicals, and local cafes have prepared for store operation without disposable cups, and since the 23rd of last month, 33 stores in Ulsan have been offering drinks in Dodori cups. In this system, customers who purchase drinks at a store pay a deposit of KRW3,000, receive a drink in a Dodori cup, use it for takeout, return the cup to the participating cafe, and receive a refund of the deposit. In Freiburg, an eco-friendly city in Germany, 70% of the cafes participate in the disposable cup deposit service Freiburg Cup, and the return rate is about 85%. For the success of the Dodori cup project, UBC plans to broadcast the entire consultation process with local cafes, citizen participation, and cup-making as a regular program, Earth Talk in the Era of the Environment, and continue the campaign to increase the number of participating cafes. "In addition to plastic recycling, the importance of Reduce, meaning a reduction in the use of disposable products and an increase in the use of reusable products, is increasing for the sake of environmental protection," said Kim Eung-soo, head of SK chemicals' copolyester business unit. "We will continue our commitment to solving the problem of disposable plastic containers by helping the industry switch to the excellent physical properties of ECOZEN." Source SK chemicals More around Packaging

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  • From the children's room to a Circular Economy: Sustainable materials for the toys of the future

    Interview with Philipp Hummel, Head of Sustainability, Schleich Exklusiv für K-MAG Copyright: Schleich 18.10.2023 As a child, many of us could best bring our fantasy world to life with toy figures. Although the beloved miniatures have already often lasted for decades and been passed down from generation to generation, Schleich is now consciously saying "There's more!" and opting for a green transformation. A central challenge: to reconcile longevity and eco-friendliness without compromising on quality. Philipp Hummel. Copyright: Schleich In this interview with K-MAG, Philipp Hummel, Head of Sustainability at Schleich, explains how the industry giant plans to follow its ambitious path toward a circular economy, the exciting process of material selection, and how self-reflection and a spirit of innovation are leading the company toward a more sustainable future. Mr. Hummel, Schleich figures are appreciated for their durability. How will the new material selection affect this? Philipp Hummel: Sustainable play has always been firmly anchored in Schleich's DNA. For over 85 years, we have been producing high-quality and therefore very durable toys. This durability naturally reduces the ecological impact of toys. For example, we know from surveys that 91 percent of respondents have never thrown away one of our figures. To further conserve our planet's precious resources, we are working on sustainable materials for our toy figures and, as a first step, we are ensuring that all our figures will be recyclable and Cradle to Cradle® certified by the end of 2027. Even when developing new materials for our schleich® figures, quality, safety, and durability are top priorities – today and in the future. Only the materials that meet all of our high-quality requirements are approved for our toys, so that children will continue to enjoy their schleich® figures for a long time to come, and so that future generations will be able to enjoy them as well. How is the search for the perfect materials for your ambitious sustainability project shaping up? Hummel: Our multidisciplinary team from the fields of chemistry, sustainability and engineering is working at full speed to develop new, sustainable and at the same time durable materials for our toys. At the same time, we rely on the know-how of our partners and suppliers, with whom we work together on the development of new materials. Various teams at Schleich are involved in the search for the perfect material to meet sustainability goals. Copyright: Schleich In order to find the ideal material for our play figures that meets our high quality and safety standards as well as being recyclable and more sustainable, we test a wide range of different materials both in our own testing laboratories and at our partners' facilities. In addition to mechanical testing, where we primarily test the quality properties of the material, chemical testing is performed to ensure that the material is safe for people and the environment. Only when all tests have been passed successfully, the materials are approved for our toys. Which of your products are already recyclable or biodegradable? Hummel: Most of our figurines are already designed in such a way that they can be easily recycled. Unfortunately, there is currently hardly any possibility to recycle children's toys. When a toy is thrown away, it is usually sent for energy recovery or, in some countries, ends up in landfills. To change this, we have developed our own recycling program: We accept old schleich® figures and ensure that the valuable resources from which they are made are put back into circulation. However, not all of our schleich® figures are very recyclable yet, such as figures that we use glitter or glue for. That's why we continue to develop our figures and materials to make them even more sustainable and recyclable. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates How are you going about redesigning the entire product range in terms of sustainability criteria by 2027? Hummel: We have been working for several years with a large team to develop new, more sustainable materials for our figures. We can show great progress in the area of paints: Since 2022, we have started to paint our products with water-based paint. We are also working with our partners to develop materials and paints that are Cradle to Cradle® certified and are confident of launching our first products soon. We are gradually converting our product range to more sustainable materials. In addition, we are reviewing all our activities and trying to become even more sustainable in everything we do. Not only the plastic material, but also the paints for the figures play a major role in sustainability. Copyright: Schleich What other challenges do you face with these processes? Hummel: A major challenge in developing more sustainable materials for our toys is to meet our own very high quality standards while also meeting the demanding sustainability criteria of the Cradle to Cradle® standard. We have been searching for more sustainable materials that will allow us to continue to make our figures as detailed and authentic as possible for several years now, and we are pleased to be making great progress in this area. Will the toy also change from the children's perspective? Will it look or feel different? Hummel: The quality and safety of our products are Schleich's top priority. The quality, feel and look of our products are not affected by the use of more sustainable materials. Attention to detail, authenticity and high quality are and will remain our product values that define us. A schleich® lion will always be a schleich® lion and will continue to feel the way children all over the world love it. We make no compromises here. We are working at full speed to find sustainable and recyclable materials that meet these demands. The authentic Schleich feeling remains the same for the children – the most important critics. Copyright: Schleich What are the expectations for toys in 2030 – as opposed to 50 years ago? Hummel: In light of the limited resources of our earth, the importance of quality and durability of toys, but also their recyclability, is becoming increasingly important. Our figures are timeless and are often passed down from generation to generation. Thus, children today often play with the schleich® figures of their parents or even grandparents. In addition, we have set ourselves the goal of making all our figures recyclable by 2027 and having them certified according to the sustainability principles of Cradle to Cradle® in order to make a significant contribution to the recyclability of toys. Nastassja Lotz (Editorial team K-MAG) More around Plastics in Daily Life

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  • They see me rollin' - Plastics in bicycles and current best practices

    Exclusively for K-MAG Cycling has a positive impact on climate protection. Copyright: kikea3 Cycling has a positive impact on climate protection. Copyright: kikea3 04.10.2023 Anyone who chooses the bicycle as a means of transport instead of the car every day saves the environment 3.2 kilograms of climate-damaging CO2. Researchers have determined this with a sample analysis based on data from the PASTA project (Physical Activity through Sustainable Transportation Approaches). In addition, plastics can help reduce CO2 emissions from the production and transport of bicycles. They can be used in all components and therefore make cycling even more environmentally friendly. This is shown by the following examples: Off to new adventures: Lion Bike from KraussMaffei The Lion Bikes, developed by former professional racing cyclists Marcel Kittel and Tony Martin, ensure more safety for our kids in road traffic. The bike is manufactured by Weber Fibertech on an MX 1600 from KraussMaffei and has a clean look with a special paint that makes the frame glow. The frame and front wheel fork of the sustainably produced bikes are made of a new, resource-saving material mixture of high-performance polymers and recycled carbon fibres. Comparing the production of Lion bikes with conventional frames and front wheel forks made of aluminium, the CO2 emissions for each bike produced are 67 % lower. In addition, thanks to the "Made in Germany" seal of quality, supply chains and transport routes are shortened, which is also an important aspect of sustainability. Protect the environment with the Green Marathon from Schwalbe Schwalbe and Pyrum present the world's first bicycle tyre that is made from used bicycle tyres, among other things, and closes the material cycle. According to the manufacturer, the "Green Marathon" is also made from 100% fairly traded natural rubber. In addition, 100% recycled industrial carbon black (rCB) from Pyrum is used, which serves as a direct product of the recycling process and replaces fossil industrial carbon black. The production of the bicycle tyre saves more than a third of CO2eQ compared to the previous model. Pro One Aero from Schwalbe: A unique riding performance Schwalbe's next-generation aerodynamic competition tyre was developed in cooperation with Scott, Syncros and the Swiss engineering firm Radiate Engineering & Design. Schwalbe's developers have optimised the tyre shape for modern wide rims in the wind tunnel. Different constructions are used for the front and rear wheel. The focus for the front tyre was on aerodynamics and reduced weight. During the development phase, numerous professional teams and triathletes were involved and have already put the tyre to the test during competitions. The first large-scale use of the Pro One Aero is planned for the Ironman World Championship in Nice and Kona. From "ocean plastics" to "motion plastics": The Urban Bike from Igus The Urban Bike from igus is the world's first completely recyclable all-plastic bicycle and is more durable and robust than other bicycles. "The plastics in the landfills of this world are becoming a valuable resource," says Frank Blase, Managing Director of igus. Another advantage: Since all components are made of plastic, the bike does not rust and you don't have to worry about maintenance. Thanks to the futuristic design of the bicycle, igus has already won the prestigious German Design Award 2023. Schwalbe's extensive recycling system In a cooperation between Schwalbe and Pyrum, a recycling system for used bicycle tyres was developed: The "Schwalbe Recycling System" enables the holistic recycling of used tyres of all brands. A special Schwalbe recycling box for used bicycle tyres is available at participating specialist retailers. With its pyrolysis system, Pyrum takes care of the mechanical processing and pyrolytic recycling of used tyres. As a result, used tyres are turned into new ones. According to Pyrum, the process saves a total of 80 % CO2. More efficient raw materials: A cooperation between Isoco, V Frames and the Lehvoss Group Isoco and V Frames will collaborate with Lehvoss Group on high-performance fibre-reinforced composites, including long carbon fibre and biopolymer carbon compounds. The main focus of further development will be on increasing the performance of the raw materials. With this step, future frames can be lighter and more impact resistant. V Frames produces sustainable bicycle frames and reduces the carbon footprint by 64% compared to traditional aluminium frame production according to an LCA by the University of Linz, Austria. In addition, V Frames and Lehvoss focus on compounds containing recycled fibres from different industries for each new frame.100% of the products are recycled into new bicycle component products at the end of their service life. The entire production takes place in Germany. Stylish and sustainable: The bicycle bag from BASF and Baesiq The new 2-in-1 bag "Pendik" from Baesiq and BASF can be used both as a shoulder bag and as a bicycle bag. The functional bag is made from sustainable polyamide that is derived from pyrolysis oil from used tyres. "With our partner Baesiq, we are actively advancing the topic of circular economy and are also looking forward to launching more bag collections this autumn," says Frank Reil, Head of Marketing and New Business Development & Sustainability Polyamides at BASF. CoreTechnology: 3D printed bicycle For the first time, the team of the software manufacturer CoreTechnologie has created a particularly light and affordable bicycle made of 3D printed aluminium components. The fully operational singlespeed version of the bike weighs only 7.1 kilograms ready to ride, yet it is highly robust and resilient and can be easily moved on differently shaped paths. An easy ride with the Maniac & Sane cargo bike Cargo bikes are becoming more and more popular and are dominating European city centres. However, an electric cargo bike weighs up to 60 kilograms, which often makes it difficult to steer it through the streets. Now, the start-up Maniac & Sane has almost halved the weight of the vehicle compared to what is available on the market with a cargo bike made of fibre composite materials and 3D-printed components. Thanks to SLS technology, it was possible to develop functional components and integrate them into the lightweight concept of the cargo bikes without having to make any compromises in terms of design or function. After all, with a bicycle you can not only explore the world, but also improve it. Sarah Dietsche (Editorial team K-MAG) More around Mobility

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  • Plastic Recycling: Plastic Waste Becomes Furniture

    Industrial designer combines plastic recycling with design and produces furniture from waste in Africa Exclusively for K-Mag Copyright: Johannes Kastner 25.10.2023 Updated on 29/10/2024: We have revised this article to include the latest developments and provide the most up-to-date information. Millions of tonnes of waste end up in our environment every year. This problem is particularly tangible in the global south. But innovative approaches and creative solutions can make a difference. Johannes Kastner focuses on one such solution: combining plastic recycling and design to not only combat the waste problem but also create social added value. In an interview with K-Mag, Johannes Kastner talks about his inspiring trip to Senegal, his newly developed manufacturing method for injection moulds and how local cooperation can contribute to global change. Plastic waste as a design material: furniture production with a focus on recycling Johannes Kastner, industrial designer and graduate of the Kunsthochschule Kassel. Copyright: Johannes Kastner Mr Kastner, in your diploma thesis you deal with "open plastic recycling in the global south". Why did you choose this topic? Johannes Kastner: I got access to this topic through a collaboration with the Austrian company Plastic Preneur and the Kunsthochschule Kassel. My project partner Raphael Nyabale from the Kankuma Refugee Camp in Kenya told me about the problems with plastic waste in the global south. During my later trips to Senegal, I saw this with my own eyes, so that my diploma thesis took up this topic. The project made me realize how important the recycling of plastic waste is for solving the waste problem in the Global South. During your study trip to Senegal, you worked with local craftsmen and women as part of the "DesignUp" project. Can you tell us more about that? Kastner: The "DesignUp" project provided a perfect platform for cooperation at eye level. Together with the craftspeople, I designed three stool models from different plastic waste and old construction steel. I think the diversity of the results from different design directions makes the project particularly meaningful. The project shows how design and plastic can be harmonized to create sustainable products. One of the stools is covered with a mesh made of PE drinking bags, which are lying around in huge masses in Senegal. The so-called sachets provide the cheapest source of drinking water in Senegal and something like that has to change. Injection molding and craftsmanship: combining innovative technologies for sustainable design Plastic connectors are used for furniture construction. Copyright: Johannes Kastner How did you go about developing the furniture pieces? Kastner: We use plastic connectors for the construction of the furniture, which combine different materials. In my studies I developed a new manufacturing method for injection moulding tools that enables us to produce injection moulded parts like the connectors in cost-effective small series. The other elements of the furniture are produced by craftsmen and women who bring the knowledge of their trade into the design process. The combination of handicraft production, injection moulding and great flexibility is a door opener for the African market. In a recycling workshop, Johannes Kastner restores furniture in collaboration with local people. Copyright: Johannes Kastner You graduated from the Kunsthochschule Kassel with a major in industrial design. How did that influence your approach to this particular recycling project? Kastner: Thanks to the Kunsthochschule Kassel, I was able to freely develop my manufacturing method and thus find the right path piece by piece. We have a diploma course in product design that allows you to study very freely. Apart from that, there has been a cooperation between the Kunsthochschule Kassel and the company Plastic Preneur for a few years now, without which I probably wouldn't have found access to this topic at all. Local recycling workshops as a model for the future: plastic as a resource for Africa What challenges do you see specifically in Africa or the Global South, and how do you address them? Kastner: I see it as the greatest challenge to create a successful transfer that combines new technologies, culture and humanity. Unfortunately, this is a difficult undertaking because the strong imprint of Western nations usually has a bitter aftertaste. The most important thing for me in my work is that the cooperation happens at eye level and that cultural realities are respected. The next step is to find the right people you can trust and to get support from companies and politicians. In my opinion, the foundation for sustainable development is only laid when something is initiated at the political level. Millions of tons of waste end up in our environment every year, which is especially challenging in Africa. Copyright: Johannes Kastner You will soon be travelling back to Senegal to realise your idea of a start-up. What is your plan look like? And what is your vision behind it? Kastner: I would like to set up a recycling workshop in the Senegalese capital Dakar recycling workshop together with motivated people from my network. The idea is for this recycling workshop to become a self-sustaining and become a model project for the establishment of my start-up, which I will which I will be founding in Kassel next year. My start-up will be a social enterprise with a focus on setting up and running such local recycling workshops in the global South. We want to work with companies and research with companies and research institutions to accelerate our developments. My vision is in line with the Precious Plastic Movement , which sees plastic as a valuable resource. Everyone has a right to an environment free of plastic waste. And to achieve this goal, especially in the Global South, simple and cost-effective means must be used to recycle the flood of plastic waste. Contact: Designer Johannes Kastner | Tel.: +49 157-85 05 11 11 | Mail: jojo.1396@web.de News: Johannes Kastner Wins Second Prize at the James Dyson Award 2024 With SOCIAL PLAST, Johannes Kastner has developed a method of using high-performance concrete (UHPC) to produce cost-effective and energy-efficient molds for the injection molding process. This technology is particularly suitable for small batches of 500 or more and is intended to make injection molding more accessible in developing regions. The jury recognized both the innovative potential and the social added value of the invention. Elena Blume (Editorial team K-Mag) More around Materials Design

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  • Thermoplastics in aircraft construction – less weight, more future

    Interview with Dr.-Ing. Frederic Fischer, former Project Manager "Large Passenger Aircraft", Center for Lightweight Production Technology (ZLP), German Aerospace Center (DLR) Exclusively for K-MAG MFFD component before transport. Copyright: DLR 20.09.2023 Every gram counts: In aviation, a weight reduction of just one kilogram can save up to 25,000 litres of fuel annually. Plastics can be the key to this. The German Aerospace Center, for example, uses carbon fibre-reinforced thermoplastics to make aircraft fuselages more resource-efficient. Within the framework of the Large Passenger Aircraft project, fundamentally new technologies have even been developed for this purpose. In an interview with K-MAG, Dr.-Ing. Frederic Fischer talks about the current challenges for aviation, the extent to which the use of plastics and the newly developed manufacturing technologies are more climate-friendly and cost-effective. Dr Fischer, what challenges is aviation currently facing? To what extent do you address them in the Large Passenger Aircraft project? Dr.-Ing. Frederic Fischer: Aviation is facing the urgent task of becoming more climate-friendly and sustainable. For decades, we relied on aluminium as the main material. But in today's world, with its increased focus on environmental protection and resource efficiency, this is no longer enough. The Large Passenger Aircraft project aims to reduce fuselage weight by 10 % and running costs by 20 %, which will revolutionise aviation. Innovative plastic component: the multi-functional fuselage demonstrator (MFFD) Dr.-Ing. Frederic Fischer. Copyright: DLR In the project, you developed a fuselage component. What is it made of? What are its special features? Fischer: Our multi-function fuselage demonstrator (MFFD) is made of a special plastic: carbon fibre-reinforced thermoplastic (LM_PAEK). Compared to aluminium, this material is lighter and also has the ability to be reshaped when heat is applied again. This makes repairs and recycling easier. What impact does the use of CFRP have on sustainability compared to aluminium? Fischer: CFRP offers numerous advantages over aluminium. Not only is it lighter and thus more fuel-efficient, but it is also recyclable. This leads to less waste and reduced energy consumption over the life cycle of the aircraft. To the LinkedIn profile of Dr. Fischer In-situ skin taping. Copyright: DLR You have redeveloped some of the technologies and tools used to manufacture the MFFD. To what extent was this necessary and what were they in detail? Fischer: Our main motivation was to make aviation more sustainable. To achieve this, we had to make the transition from aluminium structures to carbon fibre-reinforced thermoplastics in aircraft production. This transition also required the development of new manufacturing technologies. The three core innovations are: Laser-based in-situ fibre deposition: Here we use a robot that precisely heats material strips by means of a laser and deposits them in layers. This technique minimises material waste. Continuous ultrasonic welding: Instead of riveting, we use this method to connect the longitudinal reinforcements, the so-called stringers, to the outer skin. Electrical resistance welding: We use this method to weld the transverse reinforcements, the so-called formers, to the skin. To do this, a welding element in the joining zone made of carbon fibre is exposed to electricity, which heats it up and melts the components. By using these technologies, we can fully exploit the advantages of the new materials and significantly reduce the production effort. Integration of the stringers by continuous ultrasonic welding. Copyright: DLR What were the individual production steps for the MFFD? Fischer: The production took place in several specific steps: Fibre deposition: A ceiling-mounted robot used a laser to heat strips of material and lay them down in layers. This formed a laminate of fibre-reinforced plastics. Reinforcement of the outer skin: The next step was to reinforce the finished outer skin with the continuous stringers. They were attached by means of the newly developed ultrasonic welding. A robot with a precise path correction was used for this to effectively join the stringers. Application of the transverse reinforcements: Following this, the transverse reinforcements, our formers, were added by electric resistance welding. Final connection: Finally, the longitudinal and transverse reinforcements were welded together. Due to the confined working space, we combined a standard robot with a smaller lightweight robot to ensure precise welding of the fasteners. Advantages for sustainable production Integration of the ribs with the resistance welding process - the welding bridge developed in the project is used. Copyright: DLR What advantages do these new manufacturing processes bring over conventional methods in terms of production costs and sustainability? Fischer: Our new manufacturing processes reduce production time by up to 40 %, which brings significant cost savings. Since we have less material waste and can do without the autoclave process, we are also more resource-efficient. Overall, these processes increase both the economic efficiency and sustainability of production. What happens now with the MFFD shell? Fischer: After successful completion, the MFFD shell was delivered to Premium Aerotec, where the final machining took place. It will now be transported to the Fraunhofer Institute in Stade for further processing. Finally, Airbus will validate the technologies in Hamburg. These are exciting developments and we look forward to driving progress in this area. Completed demonstrator; Copyright: DLR Elena Blume (Editorial team K-MAG) More articles on this topic in K-Mag! Find out here how thermoplastic fiber composites are making flying more climate-friendly! You can read about how special surface coatings affect flying here! More around Mobility

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  • Huafeng, Cyclone and Covestro collaborate to provide sports shoes and shorts with reduced carbon footprint

    Copyright: wirestock 02.10.2023 Team Sonnenwagen, a student team from RWTH Aachen and FH Aachen, Germany, is committed to more sustainable mobility using renewable energy. With a self-constructed solar racing car, they once again plan to take part in the Bridgestone World Solar Challenge in October 2023 in Australia. The team also attaches great importance to a more sustainable sports kit. Huafeng, a leader in textile technology, supports this request by providing more sustainably made athletic shoes and shorts for team outfits. For this purpose, Huafeng used a partly bio-based polyurethane (PU) dispersion from Covestro, the main sponsor of Team Sonnenwagen. The new official team equipment provided by Huafeng features shorts and sports shoes with designs using Huafeng's newly launched HAPTIC ® textile coating system, which contains partly bio-based INSQIN ® PU dispersions from Covestro. In addition, fabrics for the garments and shoes are made by Huafeng based on Cyclone recycled polyethylene terephthalate (rPET) yarns derived from post-consumer plastic bottles. The shoe upper material is made of 100 percent Cyclone rPET, while the shorts consist of 86 percent Cyclone rPET and 14 percent Spandex for ensuring a comfortable fit. Lina Schwering, Team Manager of Team Sonnenwagen Aachen: "Our new official equipment looks fantastic – and we're particularly excited about its sustainability benefits! Combined with its excellent performance, it fits well with our vision for a more sustainable mobility future. We’re grateful for the continued support of Cyclone, Huafeng with its HAPTIC ® products, and Covestro as we pursue this vision." The next generation of textile coating The design of the sports shoes for Team Sonnenwagen was produced using Huafeng's proprietary HAPTIC® Art textile coating system with partially bio-based INSQIN® PU dispersions from Covestro. Source: Huafeng Developed by Huafeng using Covestro's partly bio-based PU Impranil ® CQ DLS/1, the HAPTIC ® Art textile coating system used for the shoes enables especially outstanding aesthetics, improved mechanical performance, and reduced production-related emissions. Thanks to its high solids content and thixotropic properties, the system allows manufacturers to achieve a high coating thickness, making it well-suited for creating coatings with detailed images and sophisticated 3D effects on apparel and footwear. Images and textures applied using the HAPTIC ® Art ink system have undergone a series of tests for properties such as flexibility, adhesion, and resistance to hydrolysis, washing, and abrasion. The excellent results demonstrate that the Art ink is particularly suitable for coating on high-performance sports footwear. In recognition of its excellent mechanical properties, Huafeng's ink coating system recently received the ISPO Best Product Award. Dr. Thomas Schmidt, Director of Innovation & Creation at Huafeng: "HAPTIC ® Art ink represents an important expansion of our aesthetic coating capabilities, offering exceptional design versatility along with substantial environmental benefits. For example, the new Team Sonnenwagen shoes deliver savings of 260 g CO 2 e per pair compared to conventionally manufactured sports shoes. We look forward to developing even more sustainable solutions that help drive the future of textile coating." Toward a more sustainable sportswear industry This is how the shorts of Team Sonnenwagen's new sports kit look like. Source: Huafeng With strong environmental credentials, this new coating system can also help meet the growing demand for more sustainable sportswear. Traditionally, sports apparel and footwear have relied heavily on virgin fossil-based PET materials and PU coatings to achieve the required performance, appearance, and durability. However, by combining Huafeng's textile coating expertise with Covestro's partly bio-based INSQIN ® PU technology, Team Sonnenwagen's new equipment proves that a more sustainable approach is possible. Dr. Torsten Pohl, Head of Global Textile Coatings at Covestro: "This new textile coating system represents a major step forward in terms of both performance and aesthetics. Covestro's partly bio-based Impranil ® CQ PU dispersion plays a major role in the shoe's strong environmental credentials, contributing around 80 g to the overall CO 2 e savings. This technology will enable garment and footwear manufacturers to create products that not only look incredible but also deliver a reduced environmental impact." Quelle Covestro AG More around Plastics in Daily Life

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  • Covestro and HiPhi launch joint laboratory on advanced material solutions for future mobility

    Copyright: duallogic Copyright: duallogic 08.12.2023 The automotive industry is making intensive efforts in decarbonization while going smarter, and innovative material solutions can make an important contribution to achieving this goal. In light of such trends, Covestro and Chinese premium electric vehicle brand HiPhi unveiled a joint laboratory at the China International Import Expo (CIIE) to advance low-carbon footprint material solutions and smart technologies for future mobility. The joint lab will mainly focus on the commercialization of low-carbon material solutions in future EV models and the establishment of relevant standards, as well as the development of next-generation smart surface technologies and battery solutions. This initiative builds upon a cooperation agreement signed between the two companies at the CIIE last year. "We're delighted to deepen our collaboration with HiPhi," said Dr. Markus Steilemann, CEO of Covestro, during the unveiling ceremony at Covestro's booth at the CIIE. "We set out to address the key challenges of future mobility with the launch of the joint lab. With our common commitment to pioneering low-carbon smart mobility and by combining our strengths and resources, we believe the lab will accelerate the automotive industry's transformation towards a smarter and climate-neutral future." Dr. Markus Steilemann, CEO of Covestro (right), and Dr. Chen Jun, Co-CTO of HiPhi, use the CIIE to present their new joint laboratory for more sustainable and innovative automotive developments. Source: Covestro "HiPhi aims to redefine the luxury brand in the new era. We are accelerating the adoption of intelligent and low-carbon technology in smart EVs to provide global users with a safe, efficient and sustainable travel experience, thereby changing the future of mobility and contributing to society," said David Ding, Founder and CEO of HiPhi. "Covestro's advanced material expertise is key to helping us achieve this vision. The establishment of our joint laboratory stems from Covestro's recognition of the innovative strength represented by HiPhi and other Chinese companies. We also aspire to empower our global partners and foster mutually beneficial relations through the CIIE." On display at Covestro's booth at the CIIE is the HiPhi Y, the latest luxury SUV that incorporates advanced polycarbonate solutions from Covestro, most notably in the headlamp and LiDAR lenses. As EV becomes increasingly smarter, the headlamp presents new opportunities in digital communication beyond lighting. On the HiPhi Y, the headlamp lenses are turned into a projector to display signs and patterns in front of the vehicle, creating an interactive interface with pedestrians and other vehicles. Covestro's high optical performance Makrolon ® AL solutions offer the needed dimensional stability, UV resistance and high transparency required for this application. In the LiDAR lenses, the Makrolon ® AX portfolio demonstrates superior performance compared to glass, including excellent infrared transmittance, shaping curved surfaces and impact resistance against stone chips. They can also endure the working environment of LiDAR at temperatures from 110 to 115 degrees Celsius for extended periods. The HiPhi Y electric SUV at the Covestro booth at CIIE is also an expression of the good cooperation between the two companies. Source: Covestro "As the mobility industry embarks on a journey towards carbon neutrality, the demand for circular, low-carbon footprint materials is growing rapidly and will only accelerate in the near future," said Lily Wang, President of the Engineering Plastics segment at Covestro. "We hope to collaborate with more like-minded companies, like HiPhi, to accelerate the decarbonization trend and pioneer smart technology development at the same time." HiPhi has been a long-term partner of Covestro since 2018. Covestro's material solutions have been applied to HiPhi's flagship models, such as the polycarbonate solutions that enable a "smart" B-pillar equipped with complex functions in the all-electric SUV HiPhi X. HiPhi Z, a smart sports sedan, employs polycarbonate grades for the touchpad switch on its steering wheel – enabling a futuristic interactive design – as well as high performance waterborne polyurethane adhesives for auto interiors. Covestro AG More around Mobility

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