Sustainability

Sustainability is a key focus both within the plastics industry and at the K trade fair in Düsseldorf. We highlight important topics for you, such as the circular economy, recycling and climate protection.

Illustration: Blau-grünes Recycling-Symbol um eine Erde, mit Blättern und Papier, auf hellem Hintergrund; Nachhaltigkeit und Umweltschutz.

Results (192)

  • Collaboration project shows: multi-layer packaging can be separated and recycled on an industrial scale

    Copyright: Olena_Mykhaylova 08.06.2023 Multi-layer films are used for a wide range of packaging materials, particularly in the food industry. The European Green Deal stipulates that packaging must be recyclable to a large extent by 2030. In the future, the details will be regulated by the Packaging and Packaging Waste Regulation (PPWR). A draft regulation was presented in November 2022. However, up until this point, the recycling of multi-layer film has proven difficult because the film is made of different materials. A collaboration project involving the companies BASF, Krones, SÜDPACK, and TOMRA has now demonstrated that it is possible to separate PET/PE multi-layer packaging into its individual components and return them to the materials cycle as raw materials. During the first industrial trial conducted at a Krones pilot plant in Flensburg, the partners were able to completely separate as much as 69 percent of the PET/PE components and partially separate another twelve percent. This approach is special as it uses the existing infrastructure only to recycle the multi-layer packaging. The basis for success: a partnership involving all members of the value-added chain Collaboration project gives proof of concept for closed recycling loop for PET-based multi-layer packaging. Source: BASF SE Decisive for the success of the project team were the collaborative efforts of the partners BASF, Krones, SÜDPACK, and TOMRA. The companies combined their know-how in order to close the loop. The first phase of the project was initiated in early 2021 when TOMRA conducted the first sorting trials with PET/PE trays. These trays had been manufactured by SÜDPACK using a "debonding adhesive" developed by BASF. SÜDPACK, a leading manufacturer of high-performance films for the packaging of food, non-food and medical products, has committed to becoming a zero-waste company. "Our contribution to the collaboration project was our long-standing expertise in lamination. Using our expert know-how in water-based lamination, we were able to develop multi-layer films that can be separated by caustic hot washing," says Carolin Grimbacher, Managing Partner at SÜDPACK who is also responsible for R&D. To close the materials cycle, the recyclable multi-layer films first have to be sorted out of the waste stream. The main determinant of success for this step was the ability of the AUTOSORT TM technology of TOMRA to separate the recyclable PET/PE trays from non-recyclable trays. "Our NIR technology made this possible because it is able to detect the multi-layer PET trays containing the adhesive of BASF. With this it's possible to sort the trays out of the waste stream and add them to the recyclables," David Rüßmann, Manager Special Projects, explains. Krones, a company that, among other things, develops plastics recycling systems, joined the project team in July 2022. At one of the company's pilot plants, trials were carried out to test whether it's possible to separate laminated PET/PE films to their single layers in an industrial scale. A standard hot washing process commonly used for PET recycling was applied sucessfully and as a result, the separated PET and PE can be re-used as monomaterials. "At our facility, we proved that the delamination of multi-layer films works. However, the separation of the films can still be improved by optimizing individual process parameters as well as, for example, the particle size of the flakes," Thore Lucks, Head of Techology Recycling Solutions at Krones, explains. The process of separating the PET and PE components of the film is based on adhesives that were specifically developed for this purpose. These adhesives are used during the lamination of multi-layer films to join different functional materials. The lamination adhesive must have the best possible adhesive strength when required, but still makes it possible to easily separate the two films when it comes time to recycle. "Our water-based Epotal ® adhesives already yielded very good results when separating multi-layer packaging in the laboratory. We consider it a huge success that we were able to completely separate 69 percent of the packaging during our very first industrial trial. We are confident that we will be able to further increase this figure by optimizing our debonding adhesive," Kresimir Cule, Commercial Marketing Industrial Adhesives, BASF SE, states. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Outlook: Further development of the lamination adhesive used The project is still ongoing. By adjusting various parameters of the recycling process and by further developing the lamination adhesive used, the project partners see additional opportunities for improving the recycling rate for plastics. The quality of the recycled materials is a major focus. The aim is to be able to re-use the PET for the manufacture of food packaging, while the PE fraction will be used as a raw material to make new packaging for the non-food industry. Studies on this will be carried out shortly. Source BASF SE More around Recycling

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  • Next-level recycling with digital innovations: Cologne-based plastics processor igus invests in start-up cirplus

    Recycling platforms designed by igus and cirplus jointly promote the regenerative plastics industry of the future Copyright: seventyfourimages 13.07.2023 Plastic products have many uses and have become indispensable for everyday life. But when they reach the end of their service life, they often end up in the incinerator. Conserving valuable resources and protecting the environment requires a sustainable plastics industry. The Cologne-based plastics specialist igus is pursuing this conservation goal with its "Chainge" recycling platform. The company has now invested in cirplus, a start-up based in Hamburg. The companies have a joint vision of closing the plastics cycle and initiating a revolution in the trade of recycled materials from technical and standard thermoplastics. The igus "Chainge" program has proven that circular economy can be easily achieved, it just needs new recyclate material options. From as early as 2019, igus recognised this requirement and has been enabling customers to have disused energy chains recycled, regardless of manufacturer. In October 2022, the "Chainge" online platform was created to provide easy digital access to recycling. The marketplace can now be used to add technical plastics to the circular economy that were previously not able to be accepted. It also enables processing companies to purchase recycled plastics with guaranteed quality standards. This change makes it easier to achieve announced recycling quotas. To further advance the digital circular economy, igus has now invested in a circular start-up, cirplus. Shaping the future of recycled plastics with digital technology Michael Blass, CEO e-chain systems at igus GmbH (left) and Christian Schiller, cirplus CEO (right), are happy about the cooperation. Source: igus GmbH While igus has had successes with technical plastics, cirplus is mainly active in the markets for standard thermoplastics. The Hamburg start-up offers disposal companies, recyclers, and product manufacturers a digital marketplace through which they can buy standardised recyclates in a reliable, traceable, cost-effective manner – worldwide. The team of technology and digital experts are therefore promoting the networking of the plastics and recycling industries. Cirplus was responsible for initiating DIN SPEC 91446 and DIN SPEC 91481 as the world’s first standards for high-quality plastics recycling. The motivation was to build reliable, transparent supply chains for plastic recyclates through the combination of digitalisation and standardisation. DIN SPEC 91446 was also awarded the DIN Prize 2022 by the German Institute for Standardization e.V. in the categories of climate protection and innovation. The common goal of making the regenerative use of plastics easier than ever before has brought igus and cirplus together. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates An investment with many opportunities "Chainge" offers igus customers quick and easy access to technical plastics recycling. In cirplus, igus now has a strong partner for the digital standard recyclates industry. In the future, customers will benefit from a network that links the recyclate trade in technical and standard thermoplastics and makes it possible to obtain everything easily and transparently from a single source. igus has 60 years of plastics experience, so it has developed a global network and offers access to consistent material flows. Add cirplus' experience and software expertise, and the path is clear for the next level of digital recyclate trading. The two companies are looking forward to the possibilities of a strategic partnership that offers potential for building the world’s largest AI platform for circular plastics. "Our efforts to expand our activities and make them usable for everyone led us to join forces with cirplus" says Michael Blass, CEO e-chain systems at igus. "With this investment, we are setting an example for people to think about sustainability and to create a network in order to be able to move more." Christian Schiller, cirplus CEO, adds, "In igus, we have found a partner who shares our values and works with us to advance digitalisation in the plastics industry with the aim of closing the cycle completely. igus' experience in the field of technical plastics coupled with our expertise in the field of digitalisation and standard thermoplastics is the ideal starting point for pursuing a closed circular economy – across all industries." Source igus® GmbH More around Circular Economy

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  • Luminescent solar collectors: Silicone makes power generation more flexible and colourful

    Interview with Prof. Dr. Guido Kickelbick, Professor of Inorganic Solid State Chemistry, Saarland University Exclusively for K-MAG Copyright: Oliver Dietze 22.05.2023 Plastics contribute to climate protection. As fibre-reinforced plastics for wind turbines or films for solar cells, they already play an important role in power generation from renewable energies. But the conventional solutions are not equally suitable for every area of application. This is where a new type of material comes into play that was developed at Saarland University. Prof. Dr. Guido Kickelbick. Copyright: Oliver Dietze In an interview with K-MAG, Prof. Guido Kickelbick talks about the new silicon-like material, its application in luminescent solar collectors and where they could be used specifically. Prof. Kickelbick, you have been researching flexible, silicone-like materials for several years. What was the goal of your research? Prof. Dr. Guido Kickelbick: We are fascinated by the excellent thermal and optical properties of flexible, silicone-like materials. So we looked into their application as LED encapsulation materials in a larger project. It turned out that certain chemical boundary conditions of the material have to be fulfilled for organic conversion dyes to be resistant under the extreme conditions on an LED. These dyes, which partially convert the blue light of the LED into red or green light to produce white light, should replace inorganic dyes doped with rare earths. We have also developed completely new silicon-like materials for encapsulating LEDs that could increase the stability of organic dyes on LEDs by orders of magnitude. Thanks to our expertise in synthetic chemistry, we were able to vary many properties such as refractive index and viscosity, which is required in many applications. In a cooperation with the University of Pisa, a material you developed has now been used for the first time for flexible solar concentrators. What is it all about? Kickelbick: We met my colleague Prof. Andrea Pucci from the University of Pisa at a conference and he was immediately fascinated by our optical materials because we are able to embed long-lasting and very efficient fluorescent dyes in flexible materials with a long lifetime. Prof. Pucci's research is in the field of luminescent solar collectors (LSC). These are plastics filled with fluorescent dyes. These dyes absorb and emit light, which is repeatedly reflected from the surfaces of the panels into the interior until it reaches the edges. There, the light escapes and can be converted into electricity via photovoltaic elements. Up to now, research has concentrated mainly on hard plastics such as polymethyl methacrylate, also known as Plexiglas. With our polymers, flexible LSCs can now also be created. Copyright: Oliver Dietze What material do you use for this? In what way is it particularly suitable for the LSCs? Kickelbick: At the moment, we use optical silicones for this application, which have a high refractive index. A dye we developed together with industry builds into the polymer structure when the silicone resin is cross-linked. This increases the stability of the overall system. However, we also succeed in incorporating other dyes. The advantages of the systems used are the high refractive index, which improves the reflection of light at the interface with the air, as well as the high transparency and chemical resistance of the polymers. In addition, we can incorporate very well-established dyes that have a high quantum yield, i.e. that convert as many of the incident light quanta as possible into an emitted light quantum. In the future, we want to use the new systems we have developed, which have even more advantages in terms of processing and durability. What advantages do the flexible collectors have over conventional components with solid plastic? Kickelbick: The biggest advantage of flexible systems is their adaptability to different structures on which the solar collectors are then mounted or attached. They are also less brittle, which provides additional protection against mechanical stress. Where could LSCs be used in the future? Kickelbick: Due to their very broadly selectable colour, which essentially depends on the accessibility of suitable dyes, luminescent solar collectors can be used as electricity suppliers wherever electricity generation is currently out of the question. For example, I could imagine LSCs as design elements on façades, such as noise barriers or building facades, or as partially transparent roofs. Elena Blume (Editorial team K-MAG) More around Renewable Energies

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  • "Chemical recycling is still in its infancy, but has huge potential"

    Interview with Jochen Schofer, Head of Sales of the Recycling Business Unit, Coperion GmbH Copyright: Coperion 16.08.2023 Mr. Schofer, what contribution can chemical recycling make to the circular economy? Jochen Schofer: In principle, it can make a big contribution. But it only works properly together with mechanical recycling. And it will only work if the circular economy is accepted not just in Germany or Europe, but throughout the world. In many parts of the world however, there are still either only fragmented waste collection systems, depositing systems and similar systems, or none at all, that are able to generate a sufficient waste stream for recycling. At the moment an increasing number of large corporations are jumping on the chemical recycling bandwagon, all of them operating internationally. There is hope that they will contribute considerably towards the implementation of the necessary infrastructure in all parts of the world. Chemical recycling has huge potential. The results that have been achieved so far are very promising. Nevertheless, chemical recycling is still in its infancy, while mechanical recycling is already established. Chemical recycling has particular potential because there are many plastics that cannot be processed mechanically, and more and more will be added. For example, in the construction sector, think of the many mixed plastics that are released when a house is demolished, or in the automotive industry. That is precisely why chemical recycling has to make a big contribution to the circular economy. Copyright: Coperion In which areas is chemical recycling superior to mechanical recycling? Schofer: The major advantage of chemical recycling over mechanical recycling is that it can be used to recycle all types of plastic. You no longer need a single type of material stream, as you do with mechanical recycling – for example, only polyethylene or polypropylene. Chemical recycling can also be used to recycle composites. However, the prerequisite is that you have a large material stream, because only then can the process be operated economically. Some large plants for chemical recycling with throughputs of up to 25 tonnes per hour are already being planned. Which recycling method does the machine manufacturer Coperion primarily rely on? Schofer: As a machine builder, we have made it our goal to support the plastics industry as best we can on its path to a circular economy. We develop solutions for chemical recycling, mechanical recycling, and even for many other processes, such as solvent-based recycling. Here, two different polymers are separated from each other, and the solvent is degassed in the extruder. We offer technologies for processing all plastic material streams, for well-sorted as well as poorly sorted ones. But the question is whether you put the energy into pre-sorting or, in the case of chemical recycling, into processing the oil quality afterwards. Because the worse the product to come out of the reactor, the more processing it requires. Here, too, it's all about economic efficiency in the end. Because the chemical recycling process is very energy-intensive, it is advisable to focus more on the upstream steps in the case of high throughputs. For smaller plants, it may also make economic sense to invest in processing the recovered oil. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Were there any technological challenges? Schofer: As pioneers in processing technology for virgin plastics, we have modified our product range in such a way that we can also serve the recycling market with innovative solutions. In recycling, we deal with contaminated materials, low bulk weights or high moisture contents. Therefore, we have made many developments, adjustments and optimisations to our technologies. Especially for chemical recycling, for example, we have developed a new technique that makes it possible to reliably degas chlorides directly in the extruder. Will the waste problem be solved through the circular economy? Both systems, mechanical and chemical recycling, are not silver bullets. Both make a great contribution to solving our waste problem, but much more needs to be done. Above all, product design should completely avoid poorly recyclable plastics. Because if more and more poorly recyclable plastics enter the market, they threaten to end up being burned instead of recycled. A great contribution would therefore be to simply not produce and use the poorly recyclable plastics in the first place. That should be our first goal for a functioning circular economy. Source VDMA More around Recycling

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  • Renewable energies: Bringing wind power forward with PU resins

    Interview with Dirk Soontjens, Director Global Wind Segment at Covestro Exclusively for K-MAG Copyright: Covestro 26.05.2023 At Covestro's Wind Technology Center, research is being conducted into making wind technology more efficient. To do this, a close look is taken at wind turbines – where are opportunities to use special materials that drive renewable energy? The big goal behind it: Climate neutrality and a circular economy. Dirk Soontjens. Copyright: Covestro In an interview with K-MAG, Dirk Soontjens explains how Covestro is optimizing and redeveloping PU resins to eventually increase wind turbine productivity – and how their customers are included in this process. Ultimately, what is their biggest finding from the research conducted at the Wind Technology Center? Just over a year ago, you put your wind technology center into operation. How can one picture it? Which different departments work together there? Dirk Soontjens: We have a dedicated team at the Wind Technology Center that deals purely with the (further) development of our materials for wind turbines. These materials include coatings, resins for the rotor blades, edge protection for rotor blades made of films or elastomers, or cable breakage and bending protection made of elastomer materials. A special focus at the Wind Technology Center in Leverkusen is on tests of the resin for rotor blades, which is tested and optimized together with customers. You work here on the optimization and new development of PU resins. Where are the resins used in wind turbines? In what way are they particularly suitable for this? Soontjens: The PU resins are used in rotor blades together with glass fibers as the "core" of the rotor blades to give them just the right mix of stability and flexibility and make them more productive – if our materials are used, wind turbines produce electricity more cheaply. PU resins have several advantages. First, in combination with the vacuum infusion process (for which we also offer machines), they bond optimally and opaquely with the glass or carbon fibers, providing optimal stability and flexibility. Second, they react out faster, making rotor blade production up to 20 percent faster. Third, they reduce the manufacturing costs of rotor blades by up to 8 percent. At Covestro's Wind Technology Center, various ways to improve wind turbines are developed; Copyright: Covestro Which steps of material development can you realize at the Wind Technology Center? Soontjens: From molecules to laboratory tests to smaller components or prototypes (but not complete blades) – this includes not only material development, but also process development and optimization for the production of components. How does Covestro involve (potential) customers in the research process? Soontjens: Customers can have many different material tests carried out by us. For our resins in particular, we offer various physical tests and stress tests on the stability, flexibility or flow properties of the resin under conditions specified by the customer. This enables us to show the customer exactly how our material behaves under the conditions that are relevant to them, and also to make slight adjustments to the formulation if necessary. So here we work closely with our current and potential customers to offer tailor-made solutions. Copyright: Covestro Why is Covestro specializing in wind power with its technology center? Soontjens: As a company, Covestro wants to become climate-neutral and is fully focused on circular economy. Converting all energy requirements to renewable energies is relevant for both. To ensure that large consumers like us always have enough green power, this must be massively expanded worldwide and be as efficient as possible. This in turn requires the right materials that make wind turbines more productive. Our materials offer these advantages – and with the massive market growth for wind energy, there is certainly corresponding sales and revenue for us as a company. What do you think was the biggest insight that came out of the research at Covestro's Wind Technology Center? Soontjens: That we can significantly reduce the process times and thus also the cycle times of the production of rotor blades and their components. Nastassja Lotz (Editorial team K-MAG) More around Renewable Energies

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  • Bioeconomy startup traceless receives millions in funding from the German Federal Ministry for the Environment

    Copyright: traceless materials 22.06.2023 The bioeconomy startup traceless has developed a nature-based, sustainable alternative to plastic. The compostable biomaterial traceless® is based on plant residues of industrial grain processing. To implement the innovative technology for the first time on an industrial scale, the company is planning to build a demonstration plant in Hamburg. The aim is to substitute several thousand metric tons of conventional plastic each year, thus saving a considerable amount of CO2 emissions, fossil resources, water and agricultural land. The project is being funded with around 5 million Euros from the Environmental Innovation Program (Umweltinnovationsprogramm) of the German Federal Environment Ministry (BMUV). May 17, 2023, Parliamentary State Secretary Dr. Bettina Hoffmann handed over the funding check to the two female founders. In her statement, Hoffmann acknowledged the great potential of the project, and the outstanding benefit for the environment and for Germany as an industrial location. Johanna Baare, Co-Founder & COO: "To make a real contribution to solving plastic pollution and the climate crisis, we need to produce our materials on an industrial scale. The planned demonstration production plant is the next step on this path, and the grant is an essential contribution to its funding." Parliamentary State Secretary Dr. Bettina Hoffmann (middle) and traceless founders Johanna Baare (left) and Anne Lamp (right). Source: traceless materials Plastics are at the center of the ecological challenges of our time. Not only do they leave behind the visible traces of global plastic pollution, their costly production from fossil resources also contributes significantly to the climate crisis. As part of a circular, sustainable economy, the bioeconomy offers a solution: Instead of fossil resources, renewable raw materials are used and processed into biobased products using environmentally friendly processes. The startup traceless materials GmbH has developed a novel bioeconomy technology: Based on plant leftovers from industrial grain processing, they produce a natural biomaterial as an alternative to plastic. The traceless® material is completely bio-based, home-compostable and plastic-free. By using plant leftovers, valuable biomass resources are preserved. The patent-pending technology is based on natural polymers, comes without potentially harmful substances and has a minimal environmental footprint: compared to plastic, 91% of CO2 emissions and 89% of fossil energy demand is saved during production and disposal. The company produces traceless® materials in the form of a granulate that can be further processed using standard technologies in the plastics and packaging industry. Thus, the material can be used in a wide range of end products – from rigid molded parts and flexible films to paper coatings or adhesives. Anne Lamp, Co-Founder & CEO: "The experts from the Ministry of the Environment and the Federal Environment Agency have comprehensively examined whether our technology actually contributes to environmental protection. The funding approval is a great confirmation of this." Many top-class visiors: BMUV's Parliamentary State secretary Dr. Bettina Hoffmann and more invited guests from politics and business development ecosystem were welcomes to our production and R&D location in the ISI-Innovation Center in Buchholz i.d.N.. Source: traceless materials Founded in 2020, the company has already implemented the technology on a pilot scale. With the aim of replacing plastics in large quantities soon, production capacities will be expanded to industrial scale. The planned plant will demonstrate for the first time that the innovative process can be implemented on an industrial scale. In parallel with the technology scale-up, the team of over 30 team members is developing pilot products made from traceless® materials with its customers and partners. Due to its innovative solution, the company is receiving funding from the EU as part of the EIC Accelerator. In addition, it has already received numerous awards, including the German Entrepreneur Award and the German Sustainability Award/Next Economy Award. Source traceless materials GmbH More around Circular Economy

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  • Unwinding in high quality: Continuously detached and recycled thermoplastic carbon fiber tapes with a new recycling approach

    Copyright: Fraunhofer IPT 17.08.2023 The sales market for plastic products is growing. At the same time, however, the environmental impact of non-degradable plastics is increasing and requires new recycling strategies. At the Fraunhofer Institute for Production Technology IPT in Aachen, researchers have developed a novel recycling process to recover the fiber composite material of used pressure tanks in a peeling process and reuse it for new lightweight products. The aim is to recycle fiber-reinforced plastics (FRP) without any significant loss of product quality. The Fraunhofer team has now succeeded in doing so in the "Tankcycling" research project: Over 90 percent of the mechanical strength properties are retained in the recycled material. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Fiber-reinforced pressure tanks – light and stable Since hydrogen is regarded as the energy storage medium of the future and since this odorless gas has to be stored under high pressure, its use in trucks or automobiles inevitably entails the question how to store it safely. This is achieved when hydrogen is stored in high-quality pressure vessels made of carbon fiber-reinforced plastics. These pressure vessels must be highly resilient and at the same time lightweight and corrosion-resistant so that they are suitable for electromobility. In the wake of the energy transition, the demand for high-quality hydrogen tanks has increased. In principle, however, other liquids or gases can also be stored in fiber-reinforced pressure tanks. Recycling carbon fiber reinforced tapes by unwinding Such pressure tanks are manufactured in a laser-assisted tape winding process: In this process, thermoplastic glass- or carbon-fiber-reinforced tape is wound over a base body made of plastic, the so-called liner. The unidirectional (UD) tape that covers the pressure tank cannot be reused in the conventional life cycle of the pressure tank and ends up in hazardous waste dumps. The recycling process patented by Fraunhofer IPT (DE 10 2016 117 559 A1), which it continued to develop in the "Tankcycling" project, makes it possible to remove the UD tape from the liner in a peeling process. In this way, this tape can be reused for other products that are also manufactured with the tape winding process. The Fraunhofer IPT researchers have developed a plant prototype with various modules: the tape passes through one in the recycling process before it is stored onto a spool at the end in another. Recycling in mini format: The tank recycling module can be connected to a robot head In downstream tests, the scientists checked the mechanical load-bearing capacity of the recycled material and the original material. Here it was shown that the recycling process did not reduce the quality of the material significantly. Destructive standard tests demonstrated that the recycled material had lost only five to ten percent of its mechanical quality compared with the virgin material. Based on these findings, the researchers were able to define the requirements for the recycling process and develop a tank recycling module. This module represents a further development of the recycling process, which was developed on a stationary test rig. In its miniaturized format, the tank recycling module can be attached to a robot arm. This innovation allows pressure tanks with their complex three-dimensional geometry to be fully recycled. In addition, the recycling process and subsequent rewinding of the tape can be automated in this setup. Reducing material consumption and environmental impact The recycling process with its implementation in the tank recycling module efficiently explores the limits of what is technically feasible while saving energy, material and costs. By recycling the fiber-reinforced plastic tapes, the process contributes to advancing the sustainable production of future thermoplastic fiber composite products that can be manufactured using the tape winding process. Source Fraunhofer Institute for Production Technology IPT More around Recycling

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  • HDPE plastics from post-consumer flows

    Copyright: Interzero 05.09.2023 Recycling service provider Interzero has developed a process to significantly improve how HDPE plastics are reused. Its patented process allows the viscosity of the recycled material to be controlled; it consequently allows blow-moulded products to be manufactured using 100% light packaging material sourced from post-consumer flows. This material had previously only been suitable for use in extrusion processes. A chemical modifier controls the viscosity of the recycled material during the mechanical recycling process, i.e. a special combination of additives modifies the flow properties of the recycled high-density polyethylene (HDPE) during processing in such a way that they become comparable with those of virgin plastics. This option allows a leap from the previous extrusion quality to a quality that's suitable for blow-moulding and that may be used to manufacture bottles. The effort required for re-sorting waste polyethylene lightweight packaging, such as the types of waste disposed of in yellow bins in Germany, is eliminated as is the need to add primary plastic that meets the so-called PCC (post consumer commercial) or PIR (post industrial) classifications. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Fiber-reinforced pressure tanks – light and stable Interzero's sorting plants separate waste packaging from yellow bins and yellow sacks in Germany into different material groups. The patented process was developed at Interzero's Centre of Excellence for Plastics Recycling in Maribor, Slovenia. This centre is the only research facility in the EU that possesses government accreditation in accordance with the ISO/IEC 17025:2017 laboratory standard and that has specialised in the development and analysis of recycled plastics. "We're able to draw on many years of experience and expertise in the development and analysis of plastics at this location," explains Markus Müller-Drexel, CEO at Interseroh+, which is Interzero's recycling alliance. The laboratory has developed steadily in recent years and is now entering the market with an expanded range of services. Five laboratories that boast modern technical equipment that's used for assessing material qualities – from mechanical, thermal, chemical and rheological properties to migrations, sensor systems and colour – are also equipped with material-processing machines and an NIR separator for simulating the behaviour of packaging during sorting. Significant savings in manufacturing Rupar Plastika in Slovenia is one of the first companies to use the new recycling process. The new development delivers significant savings in virgin materials and thus in petroleum and CO2 emissions for Interzero and its customers. The energy saved during sorting also means that CO2 emissions are even further reduced. This means better utilisation of the capacities at sorting plants in the face of ever-increasing volumes of used packaging. Manufacturers are also able to keep the standard equipment that they use to make new recycled products using blow-moulding processes. Slovenia-based Rupar Plastika is one of the first companies to take advantage of the new process. The company manufactures hollow plastic parts, including bottles and closures, for well-known manufacturers and employs a range of different plastic processing technologies, including extrusion blow-moulding, injection stretch blow moulding, injection blow moulding and injection moulding. "It's often necessary to adapt production lines to the use of new types of plastics. Interzero's new process means that such modifications are no longer required. That's both a huge time and cost benefit," says Rok Miklavčič, Head of Production and Sales at Rupar Plastika. Source Tightly Packed Magazine More around Recycling

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  • Covestro inaugurates new production line and launches new Desmopan®UP TPU series for Paint Protection Film in the automotive and wind sector

    Copyright: NomadSoul1 15.06.2023 German materials manufacturer Covestro inaugurated a new production line for high-performance Thermoplastic Polyurethanes (TPUs) that will be used for production of paint protection films (PPF). The new line is located at the company's existing site in Changhua, Taiwan. The investment and the expansion of its production capacities for high-performance Thermoplastic Polyurethanes at the site had been announced in 2022. At the inauguration of the new line, the company also launched its new Desmopan ® UP TPU series. UP stands for "Ultimate Protection". The series offers high durability, adaptability and aesthetics, protecting automotive surface coatings from harsh environmental conditions. The material can also be used to protect wind blades or screens of smart devices. "We are convinced that our customers and the TPU market enquire not just materials suppliers, but partners to jointly develop solutions. We at Covestro have the capabilities to be such a partner," says Dr. Andrea Maier-Richter, Head of TPU at Covestro. "We strive to collaborate with our customers and along the value chain to unlock the potential of Desmopan ® UP and meet the growth ambitions of core industries such as automotive and wind." A value-add solution offering increased sustainability with no compromise on quality TPU for paint protection films, as used for protecting cars like shown in this picture, will be produced in the new manufacturing line in Taiwan. Source: Covestro The global PPF market is projected to grow steadily until 2030, with the Asia-Pacific region accounting for the largest share of the overall market. The expected growth in that region in turn is driven in large part by the growth of the Chinese market. At the same time, North America and Europe are showing solid growth projections as well. The high interest in the material stems mostly from increasing attention of vehicle owners to the aesthetic condition of vehicles and particularly their surfaces. TPU is a performance benchmark in PPF for quality, long-term aesthetics and surface integrity. Covestro is one of the biggest international suppliers of TPU resins for PPF production. "We are really excited to start our new production line and launch the new Desmopan ® UP series to meet the increasing demand for high-performance PPF in the Asia-Pacific region and around the world," says Lisa Ketelsen, Head of TPU in the Asia-Pacific region. "This is a perfect example of how Covestro is committed to providing our customers with innovative, high-performance solutions to meet emerging challenges. In addition to this, we can also further develop our product range together with our customers thanks to our local R&D capabilities." In PPF, the choice of materials and its formulation play a decisive role. Covestro has put years of research into formulation and advanced manufacturing technologies to build the basis for the Desmopan ® UP-based TPUs for PPF. It provides superior UV durability, excellent hydrolysis and chemical resistance, as well as outstanding optical clarity. This ensures long-lasting performance, weather resistance, and impact resistance. In addition, Desmopan ® UP allows PPF to adapt to the complex designs and surfaces of different vehicles quickly and easily. Source Covestro AG More around Renewable Energies

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  • Challenge accepted: PET recycling in Myanmar

    Interview with Ottavio Previero, Marketing Manager for SOREMA div. PREVIERO N. Srl a socio unico Exclusively for K-MAG Copyright: SOREMA 10.08.2023 Before new processes are established, an analysis of the current situation is usually carried out. For the recycling of PET bottles in Yangon, Myanmar, the Italian manufacturer SOREMA and the local recycler Commercial Plastics Co. did just that. After conducting washing and recycling tests on bottles collected there, SOREMA designed a flake production line with a capacity of 2,200 kg/h to recycle the material supplied by the customer and produce new bottles for beverages. Copyright: SOREMA In an interview with K-MAG, Ottavio Previero talks about what makes recycling the collected bottles difficult, what solution SOREMA offers for this and how the cooperation went. What are the challenges of PET bottle recycling in Yangon, Myanmar? What solution did you develop for this? Ottavio Previero : The material analysis, conducted at SOREMA's RRC laboratory, verified that most of the incoming bales of material from the local market collection, consists of small bottles between 330 cc and 1000 cc with an elevated level of contamination from PVC labels, sand, and abrasive materials. Effective removal of PVC labels has been brilliantly achieved with a combination of delabeler, wet elutriator, and material sorter. This technology achieves the highest standards required by major brand owners for their rPET. As the SEA market is rapidly evolving from PVC labels to PP labels, we would like to emphasize the importance of SOREMA technology, which removes label glue with high efficiency. How does recycling work with the machine you developed? Previero : The machines have been carefully built with high-quality components, starting with the prewash module for label removal and optimal cleaning of the material surface. This technology prepares the material for better bottle sorting and reduces the overall wear and tear on the entire line, without compromising the lifespan of the delabeler, whose first maintenance is scheduled only after months. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates To what extent do you contribute to greater sustainability with cooperation? Previero : The engineering team of CPC worked closely with SOREMA's design, production, and installation teams and the collaboration was exceptional, both in terms of clarity of information and support in managing the recycling process. Sustainability, working side by side, is achieved because post-consumer PET bottles from collection throughout Myanmar are reused, once recycled, in high percentages in the production of new PET bottles. With SOREMA's plant, the client has thus provided an industrial-scale solution to the problem of plastic pollution in Myanmar. Elena Blume (Editorial team K-MAG) More around Recycling

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  • "The goal is to create an exciting vision that our consumers want to participate in with us."

    Interview with Alexis Olans Haass, Director Sustainability, adidas PURPOSE Alexis Olans Haass, Director Sustainability at adidas PURPOSE 30.06.2019 Alexis Olans Haass is Director Sustainability at adidas PURPOSE. She heads adidas brand's sustainability program from global headquarters in Herzogenaurach, Germany. Her responsibilities include directing adidas brand's sustainability strategy, developing new sustainable innovations and business models, and coordinating sustainable product creation across adidas' business units and global creation centers. Alexis' previous work revolved around sustainable product development and clean technology with companies such as IDEO, P&G, and Transfair USA. Alexis has an MBA in Marketing, and a MS in Sustainable Systems from the University of Michigan. Their goal is to produce 11 million pairs of shoes this year using upcycled marine plastic waste. Ms. Haass, could you explain your role within Adidas? Alexis Haass: I'm the director of sustainability in Adidas Purpose. I lead the team that focuses on sustainable product and how sustainability impacts our brand strategy. We work with teams across the company to determine which sustainable innovations we need, what new business models we should pursue, how we engage our consumer - anything that goes more towards the consumer side of things. Source: Adidas Sustainability is a hugely complex process in terms of materials for products. How do you break that down into manageable chunks? Haass: So that's actually quite a challenge for us as a brand, not only on the products themselves but even just thinking on the strategy we wanted to pursue because the topic is so huge. We broke down our strategy into three areas – we call them three Loops. We're trying to make this transition from that linear economy that we all know - where we take something out of the ground, you make it into a product, and then it gets thrown away - and transition over to a natural circular economy. In order to do that, we've got three Loops that are all part of the solution. The first one - The Recycled Loop - is where, instead of that straight line, you start to bend the line back. In the Recycled Loop, you're putting waste in at the front end instead of virgin material. Parley product and our recycled polyester Moonshot fit here, making sure that we can cut off the flow of virgin material and move only onto recycled materials. For our Moonshot, we are committed to using only recycled polyester in every product and in every application where a solution exists by 2024. The next stage is the Circular Loop – not only using recycled materials, but also ensuring the product itself is circular. That it's made to be remade. Here it's not just design - you'll need new business models to ensure that products go round and round. The last Loop that we have is Bionic Loop, where we are trying to loop with nature. Products here, if not made with recycled plastic, will need to be made from nature, and – in case they ever escape the loop – should harmlessly return to nature. This is a transition we are trying to go through as a product company and as a brand. We want to engage our consumers not only in the eco-innovation we're doing, but also how these topics could apply to their lives. That's why with Parley products we focused on not just making shoes out of ocean plastic, but also on engaging consumers to make a commitment to get rid of single use plastic in their lives. With the Futurecraft Loop shoe we're trying to spur on the conversation about the need to transition to a new circular economy. The goal is to create an exciting vision that our consumers want to participate in with us. Where we can bring the power of a big brand to innovate in this space – be it in the materials, products, or even brand activation – to make inroads in this transition towards a circular economy where we loop with Nature. Source: Adidas On that very narrow level of just looking at material and material choices, how do you balance and approach materials selection of one material being better than the other? Haass: We lean very heavily on lifecycle analysis in shaping our strategy. What we don't want to do is solve a small subset of the problem over here and then create another big problem with the replacement over there. We have in our team lifecycle analysts who actually help review those innovations and who give that full picture that guides both our strategy, our products and materials. There are times when something comes out as a bit of a wash about which innovation is a better way to go, and then we go for what illustrates the story of transition better. When it comes to something that is not communicated the right way and could be perceived as greenwashing, we need to take into account if it is really going to help our consumers. Is this going to get them excited? Or maybe help them relate to a problem that's otherwise pretty intangible? If that's the case, then we could prefer one over another. Are there any instances where sustainability in terms of materials in your products has driven the aesthetic of the product? Haass: Actually both Futurecraft examples - the one we did for the Recycled Loop and the other for the Circular Loop – the sustainability of the material drove the original aesthetic. I'll talk about them one at a time. Source: Adidas Our first Parley shoe – the UN shoe – was Futurecraft. That shoe was an experiment - we had this problem of new material (gillnet pulled from the ocean and plastic bottles from the Maldives) that was not of the quality or calibre that we normally expected. We were trying to weave it into a product and find a way we could turn this threat into a thread, and so had to turn to a new technology we were trialling in the lab. When we wove in the gillnet with this new technology, it created a particular look where you see waves on the line of the shoe. The tech made somebody really be able to see and visualise that the net was a part of the shoe. The same effect wound up happening with Circular Loop, and the Futurecraft Loop shoe. We wound up with very different aesthetics and looks because of making it from just one material. The material has a natural color and behaviour properties. We're already seeing - as we go through future generations of recycling those shoes in the lab - that the colour of the material changes over time… So recycling itself creates a desirable aesthetic that tells a generational story. Does that make sense? I think we're still experimenting with what people would and wouldn't accept. Consumer's interest in these topics is driving excitement around some of these new aesthetics. Recycled used to be a dirty word - in fact anything that gave you a visualisation of that felt sort of crunchy in a way that most mainstream consumers didn't want. Talking about ocean plastic, enabling people to visualise and understand the plastic problem, is starting to change the desirability of recycled products. If you get it right in positioning the topic in such a way that it can grab consumers, actually that preference around aesthetics will start to change. So, I don't think it's a permanent thing, I think it's more a question of how much resonance you've been able to create and how simple and clean of a story for consumers to touch them in the right way. Not preachy, but in a more exciting, innovative way that makes them desire that future coming; and then they're all on board. In terms of these new types of materials, which generally have higher costs or are hard to get hold of how do you scale up from new and innovative materials? How do you overcome that at Adidas? Haass: So, at Adidas we have this thing called Futurecraft. Essentially this is our way of opening up our doors and letting people see in when our innovation is pretty far along but not fully baked. That's what we did at the beginning with Parley - we opened it up and we launched initially with one concept shoe. We were trying to create the demand or the desire for recycling where it otherwise wouldn't be, where it made no cost sense for it to be, such as plastic from beaches or from small island communities. We've been able to drive huge scale by positioning the topic right – by sending the call out to the industry while also making it exciting for our consumers, there's more demand for that story. But we need to make sure we're not only driving up the demand for ocean plastic, but for recycling overall. That's why we are also talking about our recycled polyester Moonshot, where we've committed to having 100% of our polyester, which is also the material that we use the most of, transition fully to recycled by 2024, in every product and on every application where a solution exists. When you couple those together - the very good story and visualisation at the top and then a big call and commitment with the Moonshot material behind it - you generate consumer demand and awareness with our supply base on the outside, as well as mobilise people on the inside. The pull effect moves quite quickly. We've created a replicable model with Futurecraft in this space. With the UN Parley shoe, we have a track record - going from a concept shoe to producing 11 million pairs of shoes with Parley Ocean Plastic by the end of 2019. You can really build scale if you couple the inspiration at the top with a big Moonshot plan at the bottom. Have you had feedback from retailers such as Footlocker about the projects, any of them? In terms of the aesthetics? Haass: Oh gosh, yeah. What we've seen from our key accounts is that they all really want this story, and that actually it's more of a question of trying to keep up with the demand of landing that story in the right way and making sure it comes across. We don't want to just sell products with that story, it's also about activating awareness and education around the problem we're trying to solve. That's where Run for the Oceans, RFTO, comes in. RFTO is Adidas x Parley's global mobilization initiative to encourage runners around the world to engage with the problem / raise awareness of the plastic pollution threat to the world's oceans . 60,000 runners took part in 2017, almost a million last year and around 2.2 million people ran in 2019, raising $1.5 million, which we're investing in the education of future generations on the issue of marine plastic pollution. So for us, it's more about making sure that the story lands holistically, not the lack of demand. In fact, it's more us running behind it trying to keep up. This is what happens with opening up early with Futurecraft – putting that call out engages our wholesalers like Dicks and Footlocker, as well as engaging our key suppliers. People start approaching you afterwards saying ‘look, I see your commitment to it and we're ready to go to scale with you'. I think that's the power of putting something out before it's perfect or 100% there, to create the pull. Do you have a case study outside of Adidas that is a product that you were inspired by? In terms of how they had dealt with sustainability? Haass: Wow, there are so many. This is just me personally talking, but several of the car company models are changing the desirability around electric mobility. Tesla was quite early in that race, but there are more now. The thing that I found exciting about this moment is there used to be a perfectly functional electric car before, but those cars didn't put desirability first and foremost, so many consumers were stuck feeling they had to make a sacrifice to stick to their values. The success of Tesla has been in pulling the transition to electric forward 10 - 20 years because they made that switch to prioritizing desirability, while providing availability. If we can be so lucky as to do the same for accelerating the transition to sustainable consumer goods, driving up demand for moving away from virgin plastics and towards looping with nature… I would consider that success. More around Climate Protection

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  • VYTAL: the first digital reusable system for Take Away

    Interview with Dr. Tim Breker, Co-Founder, Finance, Marketing & HR of Vytal Global GmbH Exclusively for K-MAG Source: VYTAL Global GmbH 27.05.2021 Today, the kitchen stays cold: if you don't feel like cooking, you simply have something delivered. However, the meals often come in disposable packaging that only has a short lifespan. This bothered the founders of VYTAL, who developed a deposit-free reusable system. They prove that plastic and sustainability are not necessarily mutually exclusive. Dr. Tim Breker; Source: VYTAL Global GmbH In an interview with K-MAG, Dr. Tim Breker talks about the digital reusable system, why the containers improve the eco-balance and what incentive VYTAL offers its customers. Dr. Breker, how did you come up with the idea for your reusable packaging system? Dr. Tim Breker: We three founders used to work in business consulting. Eating lunch with the team at the office was common practice. All the waste from the single-use takeout containers really bothered us and we decided there must be a better way. A reusable system was the obvious choice. It was important to us to come up with a convenient solution. This is how VYTAL was born: we created the first digital reusable packaging-as-a-service solution for takeout, delivery, and convenience food – deposit-free using the VYTAL app. What material do you use for the packaging and why this one in particular? Is sustainability also a factor in production? Breker: VYTAL is currently collaborating with two European manufacturers. The Dutch company Mepal BV is the better-known of the two. VYTAL's reusable packaging system uses three sizes of the existing Cirqula set and adds its own color scheme and logo. The personal QR code of the Vytal bowl is a key component of the system and is affixed by a sheltered workshop that employs people with disabilities. The VYTAL bowls are made of plastic polypropylene, which is easily recyclable. They are BPA-free, leak-proof, insulating and heat-retaining. You can use them in the microwave (without the lid), in the freezer and they are dishwasher safe. We emphasize a simple design because the food of our partners is the ultimate star in this setting. Our bowls are designed to easily blend into restaurants, workplace cafeterias or supermarket venues. Each VYTAL bowl can be used at least 200 times and has a positive eco-balance after the tenth use, outperforming disposable single-use tableware. Over its life cycle, the Vytal bowl saves up to 30 kilos of carbon emissions. And the most important aspect: unlike deposit return schemes, the VYTAL system achieves a 99 percent return rate – this ensures that the reusable bowls have a positive impact on the environment and don't just end up in the cupboard. Exhibitors and products around raw materials and auxiliaries: Polypropylene Thermoplastic elastomers Adhesives and glues Starting materials, polemerisation auxiliaries What makes the system sustainable? Breker: The VYTAL reusable packaging system is eco-friendlier than traditional deposit return schemes because we achieve a higher and quicker return of reusable bowls. Thanks to the VYTAL app, our users can borrow as many VYTAL reusable bowls as they need – free of charge and without a deposit. This is key because as long as single-use (disposable) items are free, any deposit is a hurdle that prompts people to not choose reusable systems. You might say a low deposit is a small hurdle, but the lower the deposit, the lower the incentive to return the container, which is already weak to begin with when it comes to deposit return schemes. VYTAL removes this hurdle. The sooner a reusable container is returned, the more single-use packaging can be avoided. Since consumers get the full deposit back in a deposit return scheme whether they return the container on the same day or in two years (provided the vendor still exists), returns have no urgency and don’t make it to the top of the consumer "to-do-list". As a result, reusable containers start to pile up in the cupboard, which means more containers have to be produced to meet demand. We give customers 14 days to return the container free of charge, prompting 99 percent of our #bowlswithbenefits to cycle back into the system on time. Reusable containers require more resources in production compared to disposable products, which is why they must be reused multiple times to effectively save natural resources and protect the environment. Deposit/return systems depend on the principle of hope, because you cannot measure the number of uses per container. With the VYTAL system, using a personal QR code and name on the bowls is not just fun, it also allows you to measure the environmental impact. Every VYTAL reusable system participant knows how much carbon emissions he has saved. Your homepage mentions a "digital reusable packaging system" and "gamification" – what do you mean by that? Breker: Measuring the environmental benefit allows us to present "badges" and "awards" to system participants who drastically cut down on disposable waste or support the system in other ways, for example, by returning reusable containers to restaurant operators that need them the most. We use gamification to optimize the efficiency of our reusable packaging system and subsequently maximize the environmental benefits. For many, there are negative connotations to the term 'plastic' as it pertains to environmental sustainability. How do you want to prove them wrong with your system? In other words, how can you rebuild the "good reputation" of plastic? Breker: At VYTAL, we primarily show that when it comes to reusable products, sustainability and convenience are not mutually exclusive. Our reusable plastic containers are an essential aspect of this since they offer users higher quality reusable packaging and more functionality compared to disposable packaging. Digital reusable packaging systems like VYTAL can make a key contribution to ensuring that high-quality reusable plastic packaging is recognized and appreciated as a highly sustainable packaging option. Source: VYTAL Global GmbH What are your future plans and goals for your system? What are the next steps for your company? Breker: Who likes to eat from trash containers? You'd think nobody is up for that. Yet we have actually gotten used to it thanks to takeout and food deliveries. The production of disposable food packaging uses a lot of resources, but containers are only used 30 to 60 minutes before they end up in the trash. At best, they end up in waste incinerators, but in the worst-case scenario, they end up in nature. To prevent this from happening, we want to expand our assortment of reusable options and add sushi and pizza packaging and reusable packaging for convenience food. We are very fortunate that we have a distinct location advantage in Germany in a global comparison: We want to leverage decades of German consumer experience with reusable packaging to reduce packaging waste on a global scale. If we dare to dream, VYTAL will become THE operating system for no-deposit reusable packaging in five years and Germany’s top export worldwide. Kyra Molinari (Editorial team K-MAG) More around Circular Economy

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Topics covered in K-Mag

Sustainability

Sustainability

Digitalisation

Digitalisation

Machinery & Production

Machinery & Production

Raw materials

Raw materials

Science

Science

People

People

Plastics in Practice

Plastics in Practice

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