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)

  • Sustainability thanks to the circular economy

    New paths for the plastics industry Exclusively for K-Mag 26.06.2024 What is the circular economy? The circular economy is an economic model that focuses on sustainability and resource conservation. The aim of the circular economy is to optimize the use of raw materials and minimize waste by keeping products, materials and resources in a closed loop and keeping them in the economic cycle for as long as possible. By definition, the circular economy regards waste products as secondary raw materials that can be returned to the production cycle through recycling processes. In Germany, the sustainable circular economy is promoted by various laws and regulations in order to reduce environmental pollution and increase efficiency in the use of natural resources. Advantages of the circular economy The circular economy offers numerous advantages that include both ecological and economic aspects. Through the principle of reusing, repairing and recycling products, the circular economy reduces the amount of waste and the need to extract new raw materials. This helps to conserve natural resources and reduce pollution. Companies that implement circular economy models can reduce their costs for materials and at the same time increase their competitiveness through innovation. Customer relationships can be strengthened by offering sustainable products and services, which has a positive impact on the company's image. In addition, the circular economy promotes the creation of new jobs , particularly in the areas of recycling and sustainability. The reduction of greenhouse gas emissions through more efficient use of materials also makes an important contribution to climate protection . Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates The challenges of implementing a circular economy The implementation of a circular economy faces numerous challenges that affect both economic and ecological aspects. A central circular scheme in the economy aims to use resources efficiently and minimize waste. In Germany, circular economy recycling is being intensively promoted in order to feed waste materials back into the production process as secondary raw materials. One of the biggest challenges is the integration of sustainable practices into existing production and consumption processes. This requires investment in new technologies and an adaptation of the infrastructure. In addition, consumers need to be made aware of the issue and encouraged to rethink. The legal framework must also be constantly adapted and optimized in order to support the circular economy in waste management and create ecologically and economically viable incentives. The implementation of material cycles in industry must be further advanced. Copyright: envato Current status of the circular economy in the plastics sector The circular economy in the plastics sector is a dynamic field that deals with the sustainable use and reuse of plastic materials. Progress in this area includes the development of bio-based and biodegradable plastics, innovative recycling technologies and improved collection and sorting processes. Companies and research institutions are working together to improve the life cycle analysis of plastic products to reduce their environmental impact. Political measures, such as increasing the recyclate rate in new products and promoting closed material cycles, play a key role in promoting the circular economy. The reduction of plastic waste, the avoidance of microplastics and the implementation of standards for the circular economy in companies continue to pose challenges. The development towards a circular economy is not only essential for the environment, but also offers economic opportunities through increased efficiency and the creation of new markets. If you would like to find out more about chemical recycling, you may be interested in this interview with Jochen Schofer, Head of Sales of the Recycling Business Unit at Coperion GmbH! Even if consumers put products in black bottles into the recycling loop, it is not always guaranteed that they can actually be recycled. This is now set to change. Copyright: dimetradim - stock.adobe.com Waste4Future: A project to implement the circular economy in practice Seven Fraunhofer research teams are also focusing on the circular economy in the Waste4Future project (see box). In this project, everything depends on precise waste sorting to produce the purest possible recyclates. At the heart of the project: a sensor suite for sorting plants. This should also make it possible to detect black waste particles, for example. Up to now, these have not been recognized and sorted out by many systems - for example, black shower gel packaging, which then ends up in the incineration plant. Yoghurt lids are also often a problem if they have not been separated from the plastic in the pot. Both the aluminum lid and the plastic cup then end up in the aluminum cycle and thus in the smelter - and the plastic is lost for recycling. The sensor suite helps to identify substances and determines whether a sample is still suitable for recycling. Depending on the age of the fraction, mechanical or chemical recycling is conceivable. Finally, the collected data is linked and evaluated using machine learning. As a large amount of data is collected, a digital twin is also used. Dr. Gert Homm, scientist at Fraunhofer IWKS , explains in a press release on the topic: "Digital twins help to reduce the mass of data to the elementary core data and pass it on to an evaluation model that we are developing in the project and that reorganizes the previously process-led recycling chain into a material-led chain." Energy consumption and the CO2 footprint are also recorded. Overall, the system provides data on how the plastics can be optimally recycled and where they stand in comparison. At the end in December 2024, the researchers would then like to compare some components made from old plastic with new products. We are looking forward to the results! Institutes and facilities of the Waste4Future project Fraunhofer Institute for Microstructure of Materials and Systems IMWS Fraunhofer Institute for Non-Destructive Testing IZFP Fraunhofer Research Institution for Materials Recycling and Resource Strategies IWKS Fraunhofer Institute of Optronics, System Technologies and Image Exploitation IOSB Fraunhofer Institute for High Frequency Physics and Radar Techniques FHR Fraunhofer Institute for Structural Durability and System Reliability LBF Fraunhofer Institute for Process Engineering and Packaging IVV Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Optimizing the circular economy through Industry 4.0: the PlasticBOND project The Institute of Plastics Processing in Industry and the Skilled Crafts (German: Institut für Kunststoffverarbeitung - IKV) at RWTH Aachen University is also conducting targeted research into optimizing the circular economy. For example, the PlasticBOND project is working with industry to find solutions that can be integrated into Industry 4.0 and lead to better product developments and processes, for example for recyclates. The aim is also to improve the sustainability of plastic material cycles through digitalization. It is also being examined whether and how a material passport for products can play a role in this. Anyone wishing to find out more about the project can do so here (website in German only). Copyright: Parradee - stock.adobe.com The importance of the circular economy for a sustainable future The circular economy will definitely play a central role in a sustainable future. By minimizing waste and maximizing the reuse of resources, companies are helping to conserve natural resources. The implementation of circular processes in waste management is therefore essential. It not only promotes sustainability, but also efficiency and cost-effectiveness in production and consumption. Companies that are committed to the circular economy are often pioneers in innovation and sustainability practices. They design their business models so that products and materials are managed in closed loops, leading to a reduction in environmental impact and the creation of sustainable value. In summary, the circular economy is an indispensable part of sustainable development and offers both environmental and economic benefits. Plastic recycling should be a matter of course, says Fridolin Pflüger from HolyPoly. Read the interview to find out why and how he wants to contribute to this! Simone Ernst (Editorial team K-Mag) More around Circular Economy

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  • French start-up transforming waste plastic into seating for the Paris Olympics

    From waste to win: shampoo bottles become stadium seats Exclusively for K-Mag These white arena seats intentionally show the flecks of color to provide a recycled plastic aesthetic. Copyright: Le Pavé 17.07.2024 This article has been updated! We have revised this article for you to include the latest developments and provide the most up-to-date information. For Marius Hamelot, the 2024 Summer Olympics in France will provide a glimpse into his vision of turning trash into treasure. An architect and entrepreneur, the 29-year-old Hamelot has been working for several years to transform waste plastic collected in local Parisian neighborhoods into high-quality, durable products. Marius Hamelot helped start Le Pavé in 2018. Copyright: Le Pavé Hamelot co-founded his company, Le Pavé , along with longtime friend Jim Pasquet in 2018. The following year the firm patented a thermal compression molding technology for use in the building sector. In 2023 they earned another patent, for the process itself. "We contacted about 200 plastics companies, and we worked with about 15, but no one could do what we wanted," Hamelot said. So they created their own. Using its novel technology Le Pavé and its partners have molded, cut and shaped some 11,000 seats from recycled plastic bottles and caps for use in two Olympic arenas –– the Arena at Porte de la Chapelle in Paris and the Olympic Aquatic Centre in Seine-Saint-Denis, just northeast of the capital. Those seats alone will consume about 100 metric tonnes of waste HDPE, according to Hamelot. Le Pavé co-founder Jim Pasquet. Copyright: Le Pavé Expanding production in France Le Pavé now has two plants, having recently begun production at its second facility in Bourgogne, in the city of Allériot. The new plant will have the ability to transform 1,000 tonnes of plastic a year into panels measure up to 240 by 135cm (about 8 feet by 4.4 feet), in thicknesses ranging from 5 mm up to 15 mm (0.2 to 0.6 inches). The new plant quadrupled the company’s production capacity, according to Hamelot. The firm's first plant in Aubervilliers, France, produces smaller panels –– up to 140 x 90 cm –– out of HDPE or polystyrene . This facility produced the panels used to make all 11,000 of the seats for the Paris Olympics, set for next July 26-Aug. 11. Find out how HDPE can also be used in this news item! Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates The Games' organizers have promised to make them the greenest Olympics yet , stating "Our goal is to halve the emissions arising in relation to the Games, while offsetting even more CO2 emissions than we will generate." One of the two Paris Olympic arena installations that together will consume 100 tonnes of plastic waste to produce 11,000 seats. Copyright: Le Pavé Previous Summer Games emitted an average of 3.5 million tonnes of carbon dioxide. Paris 2024 considered this as its starting point and has developed a pioneering tool to gauge its carbon footprint and is applying a methodology to measure and control its emissions. Using recycled HDPE seating in two of its venues is one small step toward achieving this. The panels can be sawn, drilled, sanded or thermoformed. Copyright: Le Pavé Collaborating with local firms for Olympia "For the Olympic Games," Hamelot said, "we were contacted three to four years ago. We work with five companies –– two for the molding of the product. Our team works at the plants where they mold our products, using our own molds. We just use their machines to melt down the panels and produce the seats." The other company called Global Concepts , near Paris –– cuts the seats from the material. All partners are located within a radius of about 100 km. Le Pavé works with three companies for the collection of the trash. Some seats are black, with the waste plastic coming from residents in St. Denis. The white plastic comes from industrial plastic waste from shampoo bottles. At its two plants in France, Le Pavé uses its patented thermal compression molding process to form panels of different sizes, colors and thicknesses. Copyright: Le Pavé For the yellow seats to be used in the Olympic pool arena, Le Pavé is working with a local collecting network called Lemon Tri SAS . The small, Paris-based recycler uses 60 collection points for bottle caps that are sorted according to color by another company that is a social enterprise that employs people in need. Speaking of the waste they collect, Lemon Tri co-founder Augustin Jaclin told the website Tomorrow's World Today: "It's collected in Seine-Saint-Denis, shredded in Seine-Saint-Denis, processed in Seine-Saint-Denis, all for a swimming pool that’s still in the area." After Lemon Tri shreds the material, Le Pavé mixes these reclaimed plastic chips to obtain the desired, even distribution of colors. It then heats and compresses the resulting materials in their customized machines. The panels made via Le Pavé's thermal compression molding process usually are black or white, but with flecks of colors. "We didn't use a regular screw on the extruder," Hamelot explains, “because we want the color to show through." This aesthetic helps to reinforce that the materials are indeed recycled. Le Pavé then smooths and sands the panels before sending them to other partner companies in France who cut and assemble them. The material can be sawn, drilled, sanded and thermoformed. Le Pavé materials are finding use in a wide variety of applications, from baseboards and countertops to furniture and items such as these lighting fixtures. Copyright: Le Pavé A diverse portfolio of end products thanks to plastic waste Le Pavé makes many products beyond seating. The company's website cites numerous building-related applications, including wall coverings, baseboards, countertops and various types of furniture and other objects. It notes that the material is perfectly suited for vertical applications, both indoors and outdoors. Hamelot explains: "We worked with a French lab to make our HDPE fire-resistant, bromine-free, halogen-free and fluorine-free." The product is water repellent, chemical-resistant and non-porous. Resistant to temperatures up to 120°C, it can even be used in a kitchen. Polystyrene tends more heat- and temperature-stable and is suitable for interior design applications, said Hamelot, adding, "We use HDPE mostly for furniture and wall cladding." Hamelot said that, going forward, each of their ideal factories will cover 3,000 square meters (about 32,300 square feet), with the ability to expand to up to 10,000 square meters. In addition to the firm’s new plant, he has hugely ambitious plans to collaborate with local partners to launch factories worldwide. The Le Pavé panels can be curved and shaped and are ideal for mounting on vertical surfaces, such as in this coffee bar. Copyright: Le Pavé "We are looking to expand by collaborating with partners," he noted. "We've spoken with many potential partners in Africa, Asia, Europe, Canada, etc. We want our partners to be able to address the material to the building sector, to architects, craftsmen, real estate companies, etc. We also want people who are excited by the project, as well. ... We aim to transform more than 100,000 tonnes of waste into sustainable resources by 2030 and become the European leader in sustainable materials." Would you like to find out more about the possibilities of waste utilisation and new products? This interview may be of interest to you! Robert Grace More around Circular Economy

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  • Drink smarter: digital reusable cup from Vytal and PepsiCo

    Interview with Dr Tim Breker, Founder & CEO, Vytal Global Exclusively for K-Mag The Vytal Pepsi Cup has a personalised ID that can be read via QR code or RFID tag and can increase efficiency at large events. Copyright: Vytal 19.06.2024 Innovative partnerships drive sustainable solutions: Vytal and PepsiCo are taking reusable tableware to a new level in their cooperation. With individual IDs for each cup, which can be read using a QR code or RFID tag, efficiency at large events is increased enormously. The technology not only optimises the return of the cups, but also the entire recycling process, thus making an important contribution to the Circular Economy. Tim Breker. Copyright: Vytal In an interview with K-Mag, Vytal founder Tim Breker talks about the digital reusable cup, how it works and how reusable can become the new normal. Dr Breker, how did the partnership between Vytal and PepsiCo come about and what are the main objectives of this cooperation? Dr Tim Breker: The technology platform for managing reusable crockery is already well established. The special thing about us is that each container has its own individual code or ID, which is managed in a similar way to a library system and used for innovative added value. With the Vytal Pepsi Cup, each cup has a unique ID that can be read using both the QR code and the RFID tag. The QR code requires a clear field of vision and can be scanned with any mobile phone camera. This method is suitable for recording individual containers. The RFID tag, on the other hand, enables large quantities of containers to be scanned quickly and accurately without having to scan each RFID tag individually. This is particularly advantageous at large events such as football matches, where returnable cups previously had to be counted manually. RFID tags can massively speed up these processes and reduce labour costs. They also open up new possibilities for automation, from counting to efficiency in dispensing and return. The digital reusable cup is made of polypropylene, achieves an average of 125 uses and can be easily recycled at the end of its life. Copyright: Vytal To what extent does this contribute to greater sustainability? Breker: The sustainability of reusable containers depends heavily on the return rate. Digital systems like ours, where each container is tracked individually, achieve a significantly higher return rate than analogue deposit systems. We can remind users to return containers and offer the option of borrowing containers free of charge. This makes users feel like they have borrowed something rather than bought it, which incentivises them to return it. Higher return rates increase the positive impact over the life of the containers and thus contribute more to reducing packaging waste. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates What are the cups made of? How long do they last and what happens to them at the end of their life? Breker: The cups are made of polypropylene, a well-researched and recyclable plastic. Their lifespan depends heavily on how they are used. Food containers have a lifespan of around 200 uses, whereas cups have a much longer lifespan as they are not worn out by cutlery. With a return rate of 99.2%, our cups achieve an average of 125 uses. At the end of their life, we collect the containers and return them to manufacturers as a high-quality recycling stream. Vytal wants to make reusable the new normal. Copyright: Vytal What challenges do you face when implementing a reusable system? How do you overcome them? Breker: One of the biggest challenges is changing consumer behaviour. Particularly where reusable cups are not mandatory, they need to be persuaded to use reusable cups instead of disposable cups. Disposable cups are often the default setting, especially in cafés and fast food outlets, which is disastrous from an environmental perspective. We see great potential for reusable cups as a more sustainable and higher quality solution, as is the case with the Vytal Pepsi Cup. At events, we have noticed that organisers are increasingly only using reusable tableware, which makes it easier for consumers to change their behaviour. Anyone who wants to eat or drink something at the event will then inevitably do so from reusable packaging and save valuable resources. What measures are you taking to improve the reusable value chain as a whole – from distribution to take-back? Breker: We take a more comprehensive view of the reusable value chain, starting with the manufacturer and the raw material right through to recycling the containers at the end of their life. Thanks to individual traceability, we offer great added value for everyone involved. We work closely with manufacturers and have developed a model in which we pay for containers per use. This makes the manufacturers' business model sustainable and economically more attractive. Organisers and dishwashing centres benefit from unprecedented transparency regarding the whereabouts and use of the containers and save valuable manual work, e.g. for counting. Find out more about Vytal and its reusable system in this interview! Digitalisation and sustainability are closely linked for Vytal: The reusable containers can be scanned and borrowed via smartphone. Copyright: Vytal What are the advantages of all these measures, both for companies and for consumers? Breker: The economic and efficiency benefits are enormous. At the same time, it is important that we change our consumer behaviour and reduce single-use plastic. Reusable packaging is an often underestimated lever for achieving this. Our experience shows that the switch to reusable packaging works smoothly after a short period of familiarisation and becomes the new normal. This is crucial in order to reduce the exploitation and pollution of our planet. A look into the future of the plastics industry: what role do you think digitalisation and the networking of reusable solutions will play here? Breker: Digitalisation will play a central role. Our technology platform makes it possible to utilise the life cycle of containers economically and at the same time ensure access to high-quality recycling streams at the end of life. This makes economic and ecological sense, as we use resources more efficiently and need to produce less new plastic. We are working on providing the necessary infrastructure and data readiness for this transformation and are open to collaborations with companies in the plastics industry to accompany this change. The start-up MealGood has developed a reusable system especially for large-scale catering. Find out more in this interview with founder Laura-Marie Schulte! Elena Blume (Editorial team K-Mag) More around Circular Economy

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  • Recycling solutions for a sustainable future

    Wild plastic from the environment Exclusively for K-Mag The littering of the oceans and large areas of land, especially in poorer countries, is unfortunately a sad fact. Collecting this "wild" plastic can help to reduce the amount of waste a little. Copyright: envato 10.07.2024 WILDPLASTIC® has set itself the goal of ridding the world of “wild” plastic waste and offering innovative recycling solutions. The Germany-based company differentiates its products through the unique use of plastic that is recovered from the environment to be recycled and reused as granulate. In an interview with K-Mag, Christian Sigmund, CEO & co-founder of WILDPLASTIC®, explains the challenges involved in developing packaging made from wild plastic, how the environmental impact of this packaging compares to conventional solutions and how international cooperation with collection organizations works. Christian Sigmund. Copyright: Anna Ziegler How did the idea for WILDPLASTIC® come about and what was your goal? Christian Sigmund : On our travels, we stood on the mountains of garbage around the world, and we realized: We can't go on like this. We are extracting more and more fossil fuels from the ground worldwide and making too little use of the available resources. Only 9% of the world's plastic waste is recycled, 12% is incinerated and 79% ends up in the environment. WILDPLASTIC® was founded with the mission of freeing the world from wild plastic waste. What exactly is WILDPLASTIC® and how does it differ from other types of recycled plastic? Sigmund : Wild plastics are those plastic products that do not end up in a recycling loop after use but are disposed of in the environment. This includes illegal landfill sites as well as the cityscape and nature. We have established the world's only supply chain for wild plastic and, together with our local partners, we are continuously recovering wild plastic from the environment and returning it to the recycling cycle. Development and collaboration challenges for the perfect packaging Together with Goldeimer (Website in German), you have found a way to pack toilet paper rolls with WILDPLASTIC®. The development of your packaging solution took a total of three years. What challenges did you face during this process and how did you overcome them? Sigmund : The challenge is that plastic rescued from the environment is contaminated to varying degrees and the smallest inclusions can quickly cause the new film plastic to tear. A hygienic product requires flawless packaging. The result is high-quality packaging with 50% WILDPLASTIC® and 50% virgin plastic. What makes WILDPLASTIC® particularly suitable for packaging products, especially in the hygiene sector? Sigmund : Plastic is basically a good packaging material. The decisive factor is that we use more of what is already there. The German football team Borussia Dortmund (BVB) also uses WILDPLASTIC® mailing bags for its fan store. How did the cooperation come about? Sigmund : The lightweight material of our mailing bags can be filled flexibly and is ideal for sending textiles, for example. The mailing bags are 100% recyclable, tear-resistant and water-repellent, and can be labeled and glued. They consist of at least 80% wild plastic and save up to 60% CO2 compared to products made from virgin plastic. Mail order companies - such as the BVB fan store - are thus setting an example for real sustainability. A recycled plastic bag in leopard design. Copyright: Bernd Westphal Great environmental benefits through recycled packaging What specific advantages does the use of WILDPLASTIC® packaging offer for the environment compared to conventional packaging solutions? Sigmund : WILDPLASTIC® gives wild plastic waste a value again. Even if it seems crazy at first glance: since the extraction of oil and production of new plastic is so CO2 intensive, it is more sustainable to transport and recycle the collected film plastic. In 2023 alone, we returned almost 310 tons of wild plastic to the recycling cycle, saving around 700 tons of CO2. In addition, more than 6,700 days with better working conditions for collectors were made possible. How does WILDPLASTIC® work with international collection organizations to bring plastic waste from the environment back into the recycling cycle? Sigmund : We are currently active in India, Indonesia, Thailand and Senegal. In our cooperation, we make sure that the working conditions of collectors are improved. Because the local collection organizations are the real heroes in the plastic crisis. They are in a position to grow and, above all, to grow as a system and thus make a major contribution to solving the problem. The challenge for these organizations is that they are under enormous economic pressure. We at WILDPLASTIC® see informal waste management as a critical system part of the future. We believe that it is urgently needed not only today but also in the future to deal with all the material flows. There is a lack of a system. However, this system must first be financed, and this is only possible if we strengthen those who are already doing it today. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Copyright: envato Global sustainability movement: achieving goals together with strong partners Can you give us an insight into the future plans and visions of WILDPLASTIC®? What other projects are planned? Sigmund : We won't be able to rid the entire world of wild plastic on our own. That's why we are working with companies such as OTTO, Goldeimer, Hermes Germany and BVB. But WILDPLASTIC® can be so much more. That's why we are always on the lookout for new partners - from large corporations to small mail order companies - who will work with us to take plastic out of the environment. We will also be expanding our product range for private customers. How do you see the role of WILDPLASTIC® in the global movement towards more sustainability and a circular economy? What message would you like to send to companies and consumers? Sigmund : We see ourselves as part of many great organizations and companies that are breaking new ground. Because it takes all of us. Simone Ernst (Editorial team K-Mag) More around Recycling

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  • Digital Twin for Resource Management

    Interzero creates a digital foundation for the circular economy with the Materialkonto Exclusively for K-Mag Interzero's Materialkonto is a digital tool for optimizing the circular economy and sustainable use of resources. Copyright: Interzero 14.08.2024 The circular economy presents an increasingly complex challenge for companies. From new packaging requirements to stricter sustainability reporting regulations and volatile raw material prices – the demands are steadily increasing. Sustainability is no longer just a compliance issue but a crucial success factor. In this context, Interzero offers a solution: the Materialkonto (‘material account’). This provides companies with a digital twin of their resource and circular management. Britta von Selchow, Commercial Director at Interzero Circular Solutions Germany. Copyright: Interzero In the interview with K-Mag, Britta von Selchow, Commercial Director at Interzero Circular Solutions Germany, discusses the Materialkonto and how it helps to use resources more efficiently and increase transparency in the circular economy. Ms. von Selchow, how did the idea for the Materialkonto come about and what specific challenges in the circular economy do you aim to address with it? Britta von Selchow: Circular economy is climate protection. Closing more and more loops significantly contributes to CO 2 reduction and reduces the consumption of natural resources. Especially in a resource-poor country like Germany, it makes sense to engage with the topic of circularity of products at the business model level. Physically building loops is one thing. To scale effectively, companies need a strong digital foundation. To be more specific: Circular management includes, for example, logistics management for many collection and processing sites, which can be digitally automated. Additionally, we are talking about a monetary value in the case of valuable materials, which should be transparently and reliably represented. Quick access to data, for instance for mandatory reporting, is also becoming increasingly important for companies. With the Materialkonto – the digital twin for resource management – these and other data are always transparent and immediately accessible for the company. Interzero's Materialkonto closes the cycle – from collection to production to delivery. Copyright: Interzero How does the Materialkonto work and what are its main functions for companies? Von Selchow: Together with our customers, we design three concepts for the individual cycle: a logistics concept, a motivation concept, and a technical recycling concept. The logistics concept ensures that the collection and consolidation system fits the customer and their material flows – existing partnerships are of course taken into account. The motivation concept develops incentives for collection points to return valuable materials to the cycle. Finally, the recycling concept contains information on recycling pathways and, for example, the requirements for recyclates to be used again in production. In the digital Materialkonto, our customers can then see, for instance, information on logistics or the current status of the recycling process. Additionally, valuable materials can be credited as assets or secondary raw materials can be debited, similar to a bank account. This also secures our customers' raw material supply. How does the Materialkonto facilitate compliance with new sustainability reporting regulations and other legal requirements? Von Selchow: The Materialkonto transparently represents all steps and quantities in the cycle, providing the data basis for sustainability reporting. Additionally, the Materialkonto can easily provide proof of the recyclability of packaging, for instance. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates A circular economy enables constant access to raw materials and creates potential savings in the procurement of raw materials. Copyright: Interzero What advantages does the Materialkonto offer compared to traditional resource management methods? Von Selchow: Many processes are still managed in Excel spreadsheets in the cloud, with data being updated by different partners at different times. The Materialkonto is the only digital solution on the market that can automate and scale a cycle 100% transparently. How does the Materialkonto help companies reduce their dependency on primary resources and avoid supply shortages? Von Selchow: In the area of packaging, the cycle can be summarized as follows: we collect packaging waste from our customers' customers, organize the recycling, and deliver the recyclates back to our customers' production sites. Establishing a true material cycle gives companies strategic access to secondary resources – exclusively from their own waste. For the quantities managed in the cycle, our customers are independent of supply shortages and market price developments. With the Materialkonto, our customers also always know what quantities are available when and where. This also allows for better planning of the recyclate requirements for production. What are Interzero's future plans to further develop the Materialkonto and support more companies on their path to the circular economy? Von Selchow: We try to keep the entry barriers as low as possible and offer, for example, financially manageable pilot projects. In terms of further development, we aim to make data exports to CSRD dashboards even more flexible, making reporting even easier. The more companies actively shape the circular economy with us, the closer we come to our vision of a world without waste. Read more about the circular economy in the plastics industry in our comprehensive article! With the lifecycleValueCalculator from KraussMaffei, plastics processors can increase their production efficiency and achieve their ecological goals at the same time. More in the interview! CYCLOPS closes the gap between the need for information and the supply of recycled materials. Find out all about the SKZ's digital recycling tool in the interview! Elena Blume (Editorial team K-Mag) More around Circular Economy

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  • Recycling photovoltaic modules

    The green future Exclusively for K-Mag 23.04.2024 Updated on 18/07/2024: We have revised this interview to improve readability. "Don't lose it, reuse it!" is not just the exclamation of a puppy from a well-known animated children's series when he creates new objects from supposed garbage. Rather, it shows how important the topic of ‘recycling’ and ‘sustainability’ has become in general. Renewable energy hardware, such as the photovoltaic modules that can now often be found on house roofs and balconies, are now being taken into account. According to the Bundesnetzagentur (in English: Federal Network Agency), 260,000 of these so-called ‘balcony systems’ alone were installed in 2023 - and many more will follow. In an interview with K-Mag, Dr. Sylke Meyer, Group Leader "Materials Analysis", Fraunhofer Center for Silicon Photovoltaics CSP, explains how materials, such as plastics, are laboriously extracted for recycling. Dr. Sylke Meyer. Copyright: Fraunhofer CSP Solar modules contain few but important plastic components Dr. Meyer, can you give us an overview of how the recycling of components from end-of-life solar modules is carried out, particularly with regard to plastics? Dr. Sylke Meyer : Theoretically, up to 95% of end-of-life modules can be recycled if various processes are combined. In practice, however, mechanical shredding is currently mainly used. This involves first removing the frame and the junction box/cable and then shredding the laminate of glass, plastic , and solar cells . The resulting material mixture must then be separated and cleaned using complex mechanical, physical, and chemical processes. As aluminum frames and glass account for more than 80% of the weight of a PV module, the established recycling technologies focus on these materials. What types of plastics are contained in solar modules and what challenges do they pose when it comes to recycling? Meyer : Plastics make up less than 10% of the total weight of a PV module but are essential for durability and operational safety. The spectrum ranges from ethylene vinyl acetate (EVA), polyolefin elastomers (POE) or thermoplastic olefins (TPO) for encapsulating the cells to fluoropolymers (PVF), polyamide (PA) and polyester (PET) as backing surfaces and other plastics that are used as adhesives for parts of the housing or for transparent covers instead of glass. It is precisely this complexity that poses the greatest technical challenge in recycling. Specifically, this concerns, for example, the high degree of cross-linking in EVA or the multilayer nature of the underside sheets. Could you please explain how carbon capture works in the recycling process of solar module components? Meyer : Ethylene vinyl acetate (EVA) can be effectively recycled by catalytic thermopyrolysis, for example. This process lowers the required temperature at which plastic is broken down into valuable petrochemical products. However, CO2 is released at several points in the process. Various processes can be used to capture and utilize it, e.g. by means of membranes or chemical absorption. Innovative analysis, evaluation and qualification of materials and raw materials is possible at the Fraunhofer CSP thanks to state-of-the-art equipment. Copyright: Fraunhofer CSP Material analysis and processing in the RETRIEVE project You also investigate material-specific pyrolytic polymer degradation mechanisms at the institute. Can you briefly explain the process? Meyer : This refers to the thermal decomposition of polymers in the absence of oxygen, which can produce gases such as methane, ethylene or benzene, as well as valuable liquid products and solids. To control the process as efficiently and purposefully as possible, it is important to have a precise understanding of the influencing factors. These include the polymer structure itself and the reaction conditions. In the RETRIEVE project, we are supporting our project partners with our expertise in material analysis to improve the application potential of this process for recycling and beyond. For example, we are using pyrolysis gas chromatography-mass spectrometry (py-GC-MS). This allows the polymer composition of samples to be determined and additives and/or impurities to be detected. How does the cost-effectiveness of the recycling process for solar modules compare with the production of new materials? Meyer : Economic efficiency is a challenge. Separating and processing the plastic content, for example, is not yet economically viable. However, in addition to additional political requirements for recycling quotas, I also see opportunities through scaling effects. The large volume of old modules can make the development of suitable processes worthwhile, which in turn can lead to a greater supply and therefore lower prices for recyclates. How do you see the future development of the recycling of solar module components, particularly regarding the optimization of plastic recovery? Meyer : The aim must be a genuine circular economy in which as many of the materials used in the module as possible are returned to the product cycle with the highest possible added value. An important issue here is the development of standards for functional testing so that we can assess when a module has reached the end of its life. More consideration should be given to approaches for " design for recycling " – this can be an important approach, especially when using plastics. In addition, further efforts should be made to improve the reliability and service life of the modules: The longer the modules are intact in operation, the lower the need for recycling. Would you like to find out more about renewable energies? Read more about processing renewable energies at the University of Cambridge. If you would like to find out more about recycling, this article may be of interest to you. Exhibitors on the topic ‘Plastics Products and processing’ can be found here! Would you like to read our K-Mag articles on the topic of ‘Circular Economy’? Then click here! Simone Ernst (Editorial team K-Mag) More about Renewable Energies

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  • The world's first 18 micrometer thin MDO PE film

    Leonhard Kurz presents the high-performance DM Maxliner 3D machine at drupa 2024 Exclusively for K-Mag 04.07.2024 Leonhard Kurz will be presenting new sustainable recycling solutions for PET film at drupa 2024. In a video interview, Markus Hoffmann, Member of the Board at Leonhard Kurz, explains how the company takes back and reuses used PET film to promote the Circular Economy. The DM Maxliner 3D machine, which impresses with its efficiency and versatility, is also presented. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates More around Recycling

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  • Sustainability meets innovation: The rediscovery of plastics in the textile industry

    Plastics interweave sustainability with advanced functionality Exclusively for K-Mag Plastics are indispensable in the modern textile industry due to their versatility and properties. Copyright: Mint_Images 27.03.2024 The textile industry is in the midst of a green transformation, with sustainability and recycling taking centre stage. This change is being driven by a growing awareness of the environmental impact of textile production and consumption. Plastics, particularly synthetic fibres such as polyester and nylon, are ubiquitous in the industry due to their versatility and cost-effectiveness. However, the long-term ecological consequences of their use are increasingly becoming the focus of public and scientific debate. Home textiles made of synthetic fibres are dirt-repellent, easy to clean and hard-wearing. Copyright: puhimec Versatile and innovative: plastics in the textile industry Plastics have proven to be indispensable in the modern textile industry by enabling a wide range of innovative products and revolutionising the functionality of textiles. In the home textiles industry, for example, synthetics offer solutions that are not only practical but also aesthetically pleasing. Synthetic carpets that repel dirt and are easy to clean and hard-wearing furniture covers that retain their appearance for years are just a few examples of their versatile applications. Their adaptability allows designers to experiment with a variety of textures, colours and patterns to suit different interior styles. In the sports and leisure segment, synthetics have revolutionised clothing through the development of microfibres and other advanced materials that are lightweight, comfortable, breathable and waterproof. These properties are key to keeping athletes dry and comfortable in a variety of climates. In addition, synthetics enable bright, durable designs that meet aesthetic market demands. Plastics are also indispensable in the manufacture of outdoor equipment such as tents, rucksacks and shoes, thanks to their durability and resistance to environmental influences. In the world of technical textiles, plastics are also paving the way for ground-breaking innovations in areas such as medicine, construction and the automotive industry, from implantable devices and wound dressings to materials that reinforce structures and increase the efficiency of vehicles while providing safety and comfort. It is impossible to imagine the outdoor sector without plastics. They can be found in tents, rucksacks, shoes and clothing. Copyright: Pressmaster Industry caught between progress and responsibility However, the widespread use of plastics in the textile industry has also been criticised by environmentalists. They point to problems such as microplastic pollution that accumulates in the oceans and the challenge of disposing of plastic products, which often end up in landfills or are incinerated, leading to further environmental pollution. The high consumption of crude oil for the production of plastics and the associated CO2 emissions are also viewed critically. Organisations such as Greenpeace and the World Wildlife Fund (WWF) are therefore calling for a more responsible use of plastics, including the promotion of recycling and the development of sustainable alternatives such as bio-based plastics. This criticism underlines the need for the textile industry to find innovative solutions that not only improve the functionality and aesthetics of products, but also minimise their environmental footprint. Projects such as the European Union-backed WhiteCycle endeavour to develop effective recycling methods for textiles, and companies such as Patagonia and Adidas are leading the way with initiatives to use recycled and sustainable materials. When recycling textiles, the main challenge is to separate the fibres from each other and preserve their quality during the recycling process. Copyright: myjuly Road to sustainability: recycling and bio-based alternatives The challenge of making plastics sustainable has led to innovative advances in recycling and the development of bio-based materials. Modern recycling processes, such as mechanical recycling and chemical recycling, transform end-of-life textiles into new fibres, reducing the consumption of virgin materials and lowering the environmental impact. Projects such as WhiteCycle aim to optimise the recycling of polyamide and polyester fibres in order to establish an efficient Circular Economy in the EU. A key challenge is to maintain fibre quality during the recycling process while implementing efficient separation and purification technologies. Through advanced chemical depolymerisation processes that break down plastics into their monomeric components, WhiteCycle enables the creation of a truly circular process that reduces the need for virgin material and helps to reduce environmental impact. The project brings together a wide range of stakeholders from industry, research and environmental protection to achieve these goals. The success of WhiteCycle could have a far-reaching positive impact on the textile industry by paving the way for more sustainable production and consumption models. Synthetics have revolutionised the sports and leisure segment. In the form of microfibres, they make clothing light, comfortable, breathable and waterproof. They also enable aesthetic and durable designs. Copyright: Nestea06 At the same time, bio-based plastics are gaining in importance as they offer a more environmentally friendly alternative to conventional, petroleum-based materials. These renewable raw materials, which are derived from plants such as corn, sugar cane or cellulose, reduce CO2 emissions and can be biodegradable if treated appropriately. Companies such as BASF and Covestro are leading the way in the development of such materials, which not only reduce environmental footprints but also offer new properties for specific applications. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Innovative projects and partnerships The textile industry is looking forward to a bright future through innovative projects and partnerships that combine sustainability and functionality. This includes, for example, the HSBI transfer project INCAMS, also known as InCamS@BI. An innovation campus for sustainable solutions at Bielefeld University of Applied Sciences. It focuses on research and development in the field of the circular economy, in particular on sustainable materials research to optimise plastics and their reuse. The project promotes the exchange between science, business and society through innovative formats and an interdisciplinary team to develop research-based transfer structures. INCAMS will receive 8.8 million euros in funding from 2023 to 2027 as part of the federal-state initiative "Innovative University". Research projects such as those conducted by the DITF are paving the way for a more sustainable textile industry in which plastics will play a major role. Copyright: sedrik2007 The German Institute of Textile and Fibre Research (DITF) has also made impressive progress with the development of recyclable, flame-retardant textile flooring, demonstrating that environmental sustainability does not require a compromise on functionality. The challenge in developing recyclable, flame retardant textiles is to find and develop materials that enable these properties without the use of harmful chemicals. Traditionally, flame retardancy requires the use of chemicals that can make recycling difficult or contaminate the recycled materials for further use. The DITF has researched innovative solutions where both the structure of the textile and the choice of materials are optimised to provide natural or environmentally friendly flame retardant properties without compromising recyclability. A new era in textile production The integration of plastics into the textile industry with a strong focus on sustainability and innovation promises an exciting future. The combination of advanced recycling technologies, the development of bio-based materials and the realisation of innovative projects is ushering in a new era of textile production. These developments exemplify the industry's commitment to tackling environmental challenges while improving the functionality and aesthetics of products. The textile industry is proving that through creativity, research and technological advances, a more sustainable and responsible path is possible. Stephan Weiner More around Circular Economy

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  • System technology for a green future: energy efficiency in the plastics industry

    Interview with Rüdiger Dzuban, Head of Marketing & Management Assistant, ONI-Wärmetrafo GmbH Exclusively for K-Mag In-house cooling system for supplying cooling water to various production areas. Winter relief minimises the power consumption of chillers and the waste heat is used as free heating energy. Copyright: ONI-Wärmetrafo GmbH 20.03.2024 The plastics industry faces the challenge of harmonising efficiency and sustainability without compromising on performance. With a unique portfolio of products and services, ONI-Wärmetrafo supports plastics processing companies in becoming more energy-efficient and environmentally friendly, which is of immense importance, especially in times of rising energy prices. Rüdiger Dzuban. Copyright: ONI-Wärmetrafo GmbH In an interview with K-Mag, Rüdiger Dzuban talks about the relevance of heat recovery and energy optimisation systems for the plastics industry, what the biggest challenges currently are and how they can be tackled. Mr Dzuban, at first glance ONI is not a classic K exhibitor, but at second glance it is a very important service provider for the plastics industry. Can you briefly describe why you have been exhibiting at K in Düsseldorf for many years and how the plastics industry benefits from this? Rüdiger Dzuban: By developing the world's first heat recovery and energy optimisation systems for plastic injection moulding machines in the early 1990s, we pioneered energy efficiency in the plastics industry. This was also the starting signal for us to use the K trade fair as a platform for marketing these systems. Our company's development shows that this has been successful over the years. Having started with three people in 1983, we are now the German world market leader with almost 500 employees and a unique portfolio of products and services. Today, we offer companies in the plastics industry an unrivalled range of particularly efficient plant and system technology. In view of the massive rise in energy prices and the Energy Efficiency Act passed last year, our range of services is in high demand. This means that plastics processors can find system technology from cooling systems to heat recovery, ventilation and clean room technology to dynamic mould temperature control, all geared towards the efficient and sustainable use of energy. And as we now supply customers in over 70 countries around the world with our systems, they also come to K in Düsseldorf time and again to find out about the latest ONI developments. In addition, it is also the place where the foundations are laid for valuable business contacts, which are established through trust-building dialogue in face-to-face meetings. Injection moulding machines and the ventilation system are supplied with cooling water from the container centre. The free waste heat from the cooling water and exhaust air is reused for heating - replacing primary energy sources such as natural gas or heating oil. Copyright: ONI-Wärmetrafo GmbH In recent years in particular, sustainability and energy saving have become top priorities in the plastics industry. Where do you currently see the biggest challenges and how should they be tackled? Dzuban: In my opinion, you have to look at both the ecological and the economic aspects: Ecology: plastics in the environment, microplastics in food, plastic image, recycling, circular plastics economy. Economy: consumer behaviour, energy prices, location costs or government regulations. Energy prices and other costs have risen massively. Reliable political statements are needed on where the journey is heading. There will only be a significant improvement if people's uncertainty is reduced. The energy companies should lower energy prices and their disproportionately increased profit margins should be siphoned off through taxes. The bureaucratic burden should not only be reduced through announcements, but also in everyday practice. If plastic does not become a recyclable material and the shipment of plastic as a problem material remains high as a result, we will have to pay a price that we cannot even imagine in our wildest dreams. The spectrum ranges from the costs of collection and disposal to the costs caused by damage to health. We need a price for plastic that is 5 or even 10 times higher than before. This makes it very likely that no more plastic will be disposed of in the environment. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Then it will be worthwhile for everyone to collect plastic in the yellow bin, because every kilogramme of recyclable material represents an attractive monetary value. Recycling will become a significant economic factor and recycling rates will increase dramatically for all types of plastic. Furthermore, in my opinion, a small group of experts who are not pursuing a political interest and who are able to point out lines of development and provide a corresponding action plan are needed to develop solutions. For Germany, the biggest challenge that all stakeholders and politicians must face is: "How do we make Germany an attractive and competitive location?" We will only have laid a good foundation if promising products, systems and concepts are developed here that are in demand worldwide. If we ensure that the location is competitive in order to produce such plants and systems and that our expertise is of value to customers worldwide, we will be well equipped for the future. Large 3-module containerised cooling system with three highly efficient, water-cooled chillers. One chiller is designed as a heat pump that supplies both heating and cooling energy for production in winter. Copyright: ONI-Wärmetrafo GmbH How do you assess the topic of energy-saving technology in the global plastics industry? In your opinion, which countries are already leading the way and which have the most catching up to do? Dzuban: Wherever energy costs have played a subordinate role in the past (as they have for us in the past), the topic of energy efficiency and sustainable energy utilisation has simply been neglected. In the meantime, the European energy price picture has changed drastically. As a result, this issue has become much more important in all European countries, with the exception of Scandinavia (hydroelectricity) and France (nuclear power). Nevertheless, as with us, it takes a certain amount of time for such a wheel to start moving. The improvement in the efficiency of machines and systems through optimisation measures can be demonstrated very well by measuring energy consumption before and after optimisation. Copyright: ONI-Wärmetrafo GmbH In the meantime, Germany has taken on an absolute pioneering role with regard to the use of energy-saving technology because energy prices have "gone through the roof", energy-saving measures are being promoted and climate and environmental targets are also being demanded by automotive companies from their plastics processors. This is particularly true for the plastics processing industry. For every plant we supply, whether as a refurbishment or new construction project, we provide a reliable profitability analysis and an overview of achievable savings through individual measures or holistic energy-saving concepts as early as the concept phase. In Austria, Switzerland and Poland, the topic of energy-optimised plant technology has been playing an increasingly important role for some time (and in the Czech Republic since the tripling of industrial electricity prices last year). In our view, France and Italy have the greatest need to catch up (despite very high energy prices). Elena Blume (Editorial team K-Mag) More around Climate Protection

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  • Plastic recycling in the Closed-Loop Factory: from waste acceptance to product manufacture

    Interview with Fridolin Pflüger, Co-Founder, HolyPoly Exclusively for K-Mag Whether a product can be recycled at the end of its life must be analysed in detail. Ideally, recyclability should already be taken into account during product development. The start-up HolyPoly supports brand manufacturers in all the necessary steps. Copyright: HolyPoly 18.04.2024 Recycling begins even before disposal. The entire life cycle of a product should be considered as early as the development stage. The start-up HolyPoly supports brand manufacturers throughout the entire recycling process. Their mission: to make plastics recycling a matter of course. To meet the growing demands, they recently opened the Closed-Loop Factory. Fridolin Pflüger. Copyright: HolyPoly In an interview with K-Mag, Fridolin Pflüger talks about the opportunities offered by the new Closed-Loop Factory, why the recycling process starts before the waste and how HolyPoly is helping to raise awareness of plastic recycling. You inaugurated your Closed-Loop Factory at the end of last year. How has its development affected HolyPoly's capacities and opportunities in plastics recycling? Fridolin Pflüger: This step was the right decision at the perfect time. First and foremost, we wanted to use the new technical centre to concentrate our machinery in one place in order to implement the increasing number of projects as smoothly as possible. We have purchased new machines for sorting plastics and expanded the conveyor systems so that we can meet the growing requirements of our customers. Thanks to the modular structure of our factory, various test set-ups can be flexibly connected in series to test the optimum constellation of recycling steps for series processes. This simplifies the temporary use of rental machines in particular, allowing us to dynamically adapt our technical capacities to project requirements. As a final step, we are currently planning to set up our own laboratory in the Closed-Loop Factory in order to expand our analytical capabilities. HolyPoly recently inaugurated the Closed-Loop Factory. Here, all processes relating to recycling can be modelled on a pilot plant scale. What is created here can then be transferred to industrial production processes. Copyright: HolyPoly Can you describe the process that HolyPoly goes through from receiving the plastic waste to manufacturing new products? Pflüger: Our work actually begins before the "waste", because the cycle can only be closed sustainably if recycling is considered for the entire life cycle of a product. That's why our projects often start with a discovery phase , an in-depth analysis to explore new recycling prospects in strategically important markets and regions. It would be ideal if the return and recycling of products were already planned during the development phase. However, as this is generally not the case, we use modern UX design approaches to develop ways of returning the product to the market, for example through innovative take-back systems and recycling programmes. We always optimise these for specific product groups so that we can design a customised recycling process with particularly high-quality source material. After collection, the disposed plastic products – in this case bottles and soothers from NUK – must first be sorted. They are then processed into recyclate, from which new products can be made. Copyright: HolyPoly HolyPoly invests a great deal of energy and expertise in the development of these recycling processes – from dismantling and sorting to formulations and compounding, in order to adapt the recycling material for the desired application and compensate for possible fluctuations in quality. Our new Closed-Loop Factory has become a crucial piece of infrastructure: Here, we are able to map all processes in-house on a pilot plant scale. What is created here can then be quickly transferred to industrial production processes together with long-standing and experienced partners. The final phase then begins with circular product development . The focus is now on the design, layout and manufacture of plastic products with the main objective of maximising the recyclability of the new product. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Only with the right processes can recyclates be produced that are comparable to the quality of new material. Copyright: HolyPoly What challenges do you see in the scaling of recycling processes and how does HolyPoly meet them? Pflüger: Scaling recycling processes is ultimately the key to success: the use of recycled plastics only makes economic sense once a "critical mass" has been reached. Our previous projects, for example for Bosch, have proven that with the right processes, recyclates are ultimately produced that are in no way inferior to virgin material. This applies to quality, appearance and all regulatory requirements such as pollutant guidelines and the applicable legal standards. Now we are faced with the challenge of bringing the price of the recyclate into an appropriate economic relationship with the virgin material and you guessed it: the solution is called scaling. However, we see the biggest structural obstacle in the massive investment backlog in large parts of the German economy. The energy transition is not feasible without solar and wind power plants. The same applies to the Circular Economy: without investment in the necessary infrastructure, it will remain nothing more than a beautiful dream. HolyPoly counters the low willingness to invest with facts: With the data from our feasibility studies and the test runs in the Closed-Loop Factory, we can generate very well-founded business models with a view to profitability and investment requirements. These business cases show that a competitive material price can be achieved with a high volume throughput using the latest technologies and that the investments will pay off. If one also assumes medium-term price increases for new materials – for example due to rising CO 2 taxes or crude oil prices – this will sooner or later even result in a competitive advantage. Colour-sorted plastic waste is shredded ... ... and processed into regrind. Copyright: HolyPoly Can you give us an example of a successful project that shows how HolyPoly is putting the Circular Economy into practice? Pflüger: The PlayBack recycling programme is a good example. [...] Find out more about the PlayBack project in this interview! Brand manufacturers can provide effective impetus to make the plastics industry more sustainable. HolyPoly focuses on these companies and supports them on their way to optimised recycling processes. Copyright: HolyPoly How is HolyPoly helping to raise awareness and acceptance of plastics recycling in the industry and beyond? Pflüger: The declared aim of HolyPoly is to make plastic recycling a matter of course. However, a conscious approach to plastics is only possible if there are suitable offers. For the industry, this means that preserving the value of plastics must become a key aspect of their economic considerations. In short: recycling must pay off – at least in the long term. Only with this prospect will companies be prepared to incorporate recycling and technical cycles into their business models. After all, such a transformation process requires a great deal of commitment and high levels of investment because suitable processes and infrastructure often do not exist. The major brand manufacturers in particular have a special role to play on this path: they can provide effective impetus that can transform the entire system and make the plastics industry more sustainable. This is precisely why HolyPoly is focussing on these companies. Elena Blume (Editorial team K-Mag) More around Recycling

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  • Fluoroplastics in focus: Between environmental protection and industrial needs

    The planned ban on PFAS and its impact on industry and the environment Exclusively for K-Mag Industry associations are warning of far-reaching consequences for numerous areas of application in connection with a PFAS ban. Copyright: Francesco Scatena – stock.adobe.com 23.02.2024 The debate about fluoroplastics and their environmental impact is reaching new heights. While environmentalists are calling for a ban on PFAS (perfluorinated and polyfluorinated alkyl compounds), industry associations are warning of the far-reaching consequences for numerous areas of application. A look at the arguments and challenges. Per- and polyfluorinated alkyl compounds (PFAS) are a group of chemicals that are highly resistant due to their special molecular structure, in which fluorine atoms are bound to carbon chains. This property makes PFAS useful in many applications, but also leads to their persistence in the environment and concerns about their potential environmental and health damage. Environmental concerns versus industrial necessity PFAS can be found in a large number of everyday products, for example in non-stick coatings on pans. Copyright: Krakenimages.com – stock.adobe.com PFAS are often referred to as "forever chemicals" because they can accumulate in the environment and in living organisms without degrading. Their use in a variety of products, from non-stick coatings to fire-fighting foams and waterproof textiles, has led to their widespread presence in the environment and in human bodies. As a result of these concerns, the European Chemicals Agency (ECHA) has considered the possibility of a comprehensive ban on PFAS, which could include all 38 fluoroplastics, a subgroup of PFAS. Such a ban would be one of the most far-reaching in the history of chemicals regulation and would have a significant impact on many industries. Industry associations such as PlasticsEurope, which represent the plastics industry, have expressed concerns about the potential impact of such a ban. "We support the protection of people and the environment and therefore also that everything possible is done to prevent harmful substances from being released into the environment," says Thorsten Kühmann, Managing Director of the Plastics and Rubber Machinery Association within the VDMA. "The substances used in machines are generally not hazardous to health, but are necessary for their functionality. The current PFAS regulation is a ban regulation that excludes all substances, whereas only truly hazardous substances should be excluded. This approach alone helps people and the economy alike!" Unlike many other PFASs that can accumulate in the environment and in the human body, fluoropolymers are not absorbed or accumulated in the same way due to their size and structure. This distinction is central to the debate on the proposed ban, as fluoropolymers are essential in a wide range of applications, from medical devices to renewable energy components. Exhibitors & products around raw materials & auxiliaries Thermoplastics Thermoplastic elastomers Resins & compounds Foams & intermediates Fillers To all exhibitors in this category Fluoroplastics – an indispensable component of modern technologies? Fluoroplastics, known for their exceptional properties such as chemical and temperature resistance, play a central role in many sectors of modern industry. Their chemical resistance makes them ideal for applications in the chemical industry, where they are used as coatings and seals to protect equipment from corrosive substances. At the same time, their ability to withstand extreme temperatures allows them to be used in areas that require reliable performance under difficult thermal conditions, such as the aerospace industry. In addition, they have excellent dielectric properties, making them valuable insulators in electronics and electrical systems. Their smooth surface and low coefficient of friction also make them ideal for applications where minimal friction is required. "Without fluoroplastics, there would be no Green Deal," say the Bavarian chemical associations. Copyright: Ondra – stock.adobe.com The debate surrounding the planned ban on PFAS, which includes fluoroplastics, is particularly relevant in this context. While environmentalists are calling for a ban due to the environmentally harmful and unhealthy properties of many PFAS, the industry is emphasising the unique advantages of fluoroplastics. "Without fluoroplastics, there would be no Green Deal," argue the Bavarian chemical associations, for example. At a round table on the Chamber of Industry and Commerce's PFAS ban proposal, the Bavarian chemical associations argued that the enshrined climate targets would not be achievable without the use of fluoropolymers in sustainable technologies. A ban could also have far-reaching effects on numerous branches of industry, including those that are of central importance for the implementation of the European Green Deal. In this area of tension between environmental protection and industrial requirements, the search for a balanced approach that takes into account both environmental protection and the needs of industry becomes a key challenge. Alternative solutions and future research Companies such as Amazon and McDonald's have already started to remove PFAS from their food packaging. Copyright: artursfoto – stock.adobe.com The search for alternatives to PFAS and future research in this area is focussed on developing new materials that are both environmentally friendly and efficient. One example of such a project is the EU ZeroF project, which is led by the Fraunhofer Institute for Silicate Research ISC and aims to develop PFAS-free packaging and textiles. The aim of the project is to create functional substitutes for PFAS, particularly in areas such as food packaging and technical textiles. The challenge is to develop coatings that are water-repellent but at the same time can be applied as a water-based solution, which is a requirement of the textile industry. ORMOCER® coatings, a class of hybrid materials, are being used in the ZeroF project to provide a variety of customisation options for this complex task. In addition, efforts are underway to find alternatives for PFAS in paper food packaging. These alternatives are intended to replace the high water and grease resistance properties of PFAS while minimising the health risks to humans. Large companies such as Amazon and McDonald's have already started to remove PFAS from their food packaging, and various studies and assessments are identifying safer alternatives for use in food packaging. A balanced path between the environment and the economy The debate around fluoroplastics and the planned PFAS ban shows the complexity of the challenges facing our society. While protecting the environment is of paramount importance, the needs of industry and the importance of these materials for numerous applications must be taken into account. A balanced approach that encourages innovation while taking environmental considerations into account could be the key to resolving this conflict. Stephan Weiner More around Climate Protection

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  • Chemical Recycling of Plastics: A Future Without Landfills?

    Start-up Waste-to-En converts plastic waste into valuable resources through gasification Exclusively for K-Mag The gasification technology from Waste-to-En efficiently converts plastic waste into valuable resources. Copyright: Waste-to-En 13.03.2024 Updated on 15/10/2024: We have revised this article to include the latest developments and provide the most up-to-date information. Every year, millions of tons of plastic waste are produced that are not recycled. The gasification technology of the start-up Waste-to-En enables the chemical recycling of plastics and offers a promising solution to this problem. The method efficiently converts waste into valuable resources while reducing both landfill fees and electricity consumption, providing a sustainable alternative in waste management. Sergey Likharev, Founder & CEO, Waste-to-En. Copyright: private In an interview with K-Mag, Sergey Likharev, Founder & CEO of Waste-to-En, talks about the possibilities and advantages of gasification and the extent to which this technology represents an alternative to other recycling processes. Mr Likharev, what are the mission and core objectives of Waste-To-En, particularly with regard to converting plastic waste into valuable resources? Sergey Likharev : Waste-To-En startup company's mission is to address environmental and social hazards caused by waste dumping at landfills, with a primary focus on reducing plastic pollution and methane emissions. We specialize in recycling types of waste that cannot be treated with traditional recycling methods: mixed plastics , wet biomass residuals, spoiled textiles and paper, composite cardboard, and more. Gasification as an innovative recycling process for plastic waste In a comment on a LinkedIn post of us , you emphasised gasification as the preferred method of chemical recycling of plastics. What are the advantages of this technology over other methods of chemical recycling? Likharev : Simply speaking, gasification is the most versatile recycling process , both upstream and downstream. On the upstream, it can utilize all types of carbon-containing waste, including plastics, solid communal waste, end-of-life tires, agriculture and animal waste, wood and textile scrap, etc. Gasification converts these recyclable waste to so-called synthesis gas , a mix of carbon oxide, hydrogen, and light hydrocarbons. On the downstream, syngas could be converted to a variety of valuable products like electricity, sustainable fuels or chemicals. Even today’s darling hydrogen could be extracted out of it. The role of chemical recycling for the circular economy Waste-to-En offers a plant for chemical recycling of plastic waste that can be designed to be small, compact and cost-effective. Copyright: Waste-to-En You also mentioned high energy recovery rates and low oxygen consumption in gasification. Can you explain this in more detail? Likharev : In fact, any carbon-containing waste contains a lot of hidden energy inside. Only a small fraction of it, around 15-20%, is enough to destroy the polymer composition of plastic and dismantle it into individual molecules and atoms. To achieve this process, you need an oxidation reaction to happen, where oxygen compounds with carbon and hydrogen contained in plastic. The trick is how to make this process achieve a high recovery rate of this internal energy, using as little oxygen as possible. We employ a so-called updraft counterflow reactor, which is the most energy-efficient out of all other types. Within this unit, the internal chemical reactions are so well organized that every Joule of internal energy, extracted from waste by the partial oxidation of carbon, is used to support other reactions like drying, pyrolysis, and tar cracking. Because of this high energy efficiency , oxygen consumption is low. This brings a lot of benefits. The oxidation zone in the reactor is small and very hot, sometimes exceeding 1200°C. Because of this, hazardous substances are entirely destroyed inside the reactor. Due to this and also because of low consumption of oxygen, the filtration system of outgoing syngas is efficient. Consequently, the gasification equipment could be made small, compact, and affordable. Finally, it could fit into a size of a standard 20-foot container, allowing utilization of waste straight at the spot where it is generated, without the need for transportation. Additionally, electricity produced from waste could be consumed locally. All of this allows the users of gasification technology to reduce waste landfilling and electricity consumption fees by 20-30%. Sustainability meets profitability here! Increasing recyclability through advanced technologies Gasification converts (plastic) waste into synthesis gas, which in turn can be used to create a wide variety of new products. Copyright: Waste-to-En Given your experience, how do you assess the role of chemical recycling of plastics in the context of the global waste and plastics crisis? What role do you think this technology can play in the future? Likharev : Current traditional mechanical recycling processes have limited potential; they can utilize less than 10% of plastic. Advanced thermo-chemical recycling technologies, providing the decomposition of plastic waste into individual molecules and atoms, allow us to recycle all types of plastic and thus counteract plastic pollution without attempting to ban plastic usage itself. This technology significantly improves the recyclability of plastics that were previously difficult to recycle. Furthermore, gasification technology could help resolve another huge problem: the greenhouse gas emissions from dumped waste. Landfills produce about 2 billion tons of carbon dioxide equivalent, or 4% of these emissions globally. Gasification of waste instead of its dumping could eliminate this problem, decreasing the carbon footprint from waste by 5 times. Let's dump landfills together! Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Elena Blume (Editorial team K-Mag) More around Recycling

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