Datwyler is strengthening its position with the innovative future technology of electroactive polymers and has secured this with corresponding patents. Electroactive polymers in a unique stacked design enable completely new applications in the car of the future and in the markets of the General Industry business unit. Examples include thermal management in electric vehicle batteries or haptic feedback and morphing surfaces in human-machine interface applications.
Basically, electroactive polymers convert electrical energy into sensitive and versatile mechanical motion through elastic deformation. With the patented solution from Dätwyler, it is possible for the first time to produce stack actuators on an industrial scale. Thanks to the unique stack design, conventional actuator technologies can be replaced by this more attractive technical solution in various application areas.
The advantages of the new technology include: Low energy consumption, fewer mechanical parts, low weight and volume, a robust and durable design, and noise-free operation with sensor and haptic feedback functionality. Datwyler is currently working to build the proprietary, highly automated production line at its existing Swiss plant. Lab samples are already available, and delivery of the first industrial prototypes is planned for early 2024.
Datwyler’s stacked electroactive polymers offer a wide range of novel actuator and sensor applications. Thus, they can be used to control switches, locks, valves and to operate pumps. Applications include thermal management in electric vehicle batteries, for example, as well as actuation of mechanical components, dashboard vents or valves for pneumatic massage seats for drivers and passengers.
Electroactive polymers can also realize haptic feedback and morphing surfaces for human-machine interface applications. Examples include haptic feedback on displays and on the steering wheel, or control elements morphing out of the plain surface and becoming active when approached. Discussions with existing and potential customers, as well as initial development projects, show that both vehicle manufacturers themselves and suppliers of technical systems and interiors are very interested in the new possibilities offered by Datwyler’s stacked electroactive polymers.
“Our electroactive polymers in a unique stacked design are a promising future technology that will enable completely new and diverse applications in the car of the future and in the markets of our General Industry business unit. With our strengthened expertise in electroactive polymers, we are a leading supplier for smart-rubber applications. I am convinced that the technology with electroactive polymers has the potential to become one of our high-revenue product lines in the long term.” Dirk Lambrecht. CEO
Innovative Technology Makes Flexible Packaging Recyclable
Technology from Covestro weakens the bond strength of PU adhesives
Laminated films in multilayer packaging can be separated after use
The individual materials can be recycled later
They are indispensable in modern everyday life: Flexible packaging made from several layers of film enables the hygienic and safe storage of many foods. However, the versatile packaging has a problem: sustainable disposal. After use, the bonded films in the material mix are difficult to separate from one another – and that is why such flexible packaging is unfortunately only partially recyclable.
Covestro has identified the problem – and has developed a process for recycling companies and packaging manufacturers to address this problem: In the case of multi-layer film packages laminated with polyurethane (PU) adhesive, the respective materials can be separated from one another again thanks to the new technology. The team will now present the development at the K 2022 trade fair from 19 to 26 October in Düsseldorf.
Flexible packaging made from several layers of film enables the hygienic and safe storage of many foods. But they face a problem: the disposal. At K 2022, Covestro will present a new process for separating the laminated films. This makes recycling possible.
In the process, a special separation agent specifically weakens the bond strength of the PU adhesive. Since the separation agent consists of natural ingredients and water, it is also very sustainable. For packaging manufacturers and recyclers, the process offers a major advantage: “Our know-how helps them to make better use of the residual value of their packaging and thus makes more materials available to the recycling industry,” says Thomas Fait. The New Business Development Manager for Adhesives at Covestro has led the development of the technology on a laboratory scale. “With projects like this, we contribute to achieve our corporate vision: to make the circular economy a reality. For this purpose, we work with partners from a wide variety of fields and industries and are always looking for ways how our products and technologies can help other companies become circular.”
At the K 2022 trade fair, the team will be presenting the technology to the plastics industry for the first time and looking for potential partners from the packaging and recycling industry to further develop the process together with them.
Orthex Group Moves Toward More Sustainable Raw Materials in Cooperation With Ineos Styrolution and BASF
Orthex Houseware storage products made from Ineos Styrolution’s Luran ECO materials
Biomass balanced styrene as plastic feedstock supplied by BASF
Certified production processes and materials
Orthex, a leading Nordic producer of household products, has selected a range of Ineos Styrolution’s sustainable Luran ECO raw materials for its range of Smart Store TM Compact storage products. Luran ECO is a styrene acrylonitrile copolymer (SAN) resulting from a cooperation between Ineos Styrolution and BASF. It is built on BASF’s production of styrene monomer derived from renewable feedstock based on a mass balance approach. INEOS Styrolution uses the material as feedstock in its production of new sustainable styrenics solutions. According to an independent third-party assessment, the carbon footprint of the new material is 93% lower compared to the fossil-based Luran version.
Orthex Group is a leading Nordic houseware producer that strives to make consumers’ everyday lives easier with its products. The company has long championed sustainability with a focus on long-lasting products and increasing the use of recycled and bio-based materials to replace fossilbased plastic.
As a next step, Orthex’s storage solutions brand SmartStore will start using new biomass balance based Luran ECO raw material for the entire SmartStore Compact storage range. Orthex Group’s main criteria for selecting this material by INEOS Styrolution are easy processability, compliance with food contact regulations, and a reduced carbon footprint.
Alexander Rosenlew, CEO of Orthex Group, comments: “This new raw material solution will support our long-term carbon neutrality target. Ineos Styrolution and BASF make it possible for us to offer consumers more sustainable products. This supports our target to increase the share of sustainable raw materials in our production to 80% by 2030.”
Luran ECO with significantly reduced CO2 footprint
BASF’s biomass balance (BMB) based styrene is used by Ineos Styrolution in the production of bio-attributed styrenics specialties, mainly transparent styrenics materials such as the company’s NAS family of styrene methyl methacrylate (SMMA) products and the Luran family of SAN products.
The BASF and Ineos Styrolution processes within the end-to-end mass balance based production of the new solution portfolio are certified by ISCC+.
Artur Sokolowski, Director Sales Electronics & Household EMEA at Ineos Styrolution, comments: “Orthex is an innovative and fast-moving company. I am pleased to see that we have been able to provide a solution to Orthex that helps them to reach their ambitious sustainability target.”
Biomass balanced styrene
To produce styrene BMB, BASF replaces fossil resources like naphtha or natural gas with renewable feedstocks derived from organic waste or vegetable oils. It is one way to produce styrene via a mass balance approach. Mass balance is a chain-of-custody model that keeps track of the total amount (e.g., circular or other alternative) of feedstock throughout the production process and ensures a proper allocation to the finished goods.
Raw material and plastic producers like Ineos Styrolution and BASF can thus offer products with a better environmental profile but the same features as those manufactured from fossil feedstock. The allocation process via the mass balance approach as well as the products are certified by independent auditors. Read more about BASF’s biomass balance approach (basf.com).
“BMB feedstocks on one side and feedstocks based on chemically recycled plastic waste on the other side, both replacing fossil resources, are a very appealing way to contribute to an improved carbon footprint of subsequent products,” says Stefanie Kutscher, Head of Business Management Styrene at BASF’s Styrenics Business Europe. “Alternative raw materials already in the economic cycle enable us to produce with less virgin fossil raw materials. So, both mass balance approaches aim to achieve the same.”
Xenia Thermoplastic Specialties Launches New Range of Supertough Carbon Fiber Composites
New Xecarb ST family of carbon fiber reinforced thermoplastic composites combines advanced lightweighting benefits with superior impact strength
Xenia Materials, a global leader in thermoplastic specialties, has announced the introduction of Xecarb ST, a new family of supertough carbon fiber composites custom-engineered to close a performance gap in the market and provide superior impact strength performance.
“There is a growing demand for lightweight composites in various new markets, such as sustainable mobility and unmanned aerial vehicles (UAVs), where we have identified a need for higher impact resistance than previously offered by carbon fiber reinforced composites,” says Cristian Zanchetta, Technical Manager for R&D at Xenia Materials. “Our new Xecarb ST family meets these challenges while at the same time opening new opportunities for innovative applications in existing market segments, such as sports equipment, appliances, supercars and even additive manufacturing.”
Xenia Thermoplastic Specialties launches new range of supertough carbon fiber composites.
Xecarb ST builds on the proven mechanical strengths of Xenia’s successful Xecarb range, but shows significantly higher notched impact resistance, low temperature ductility and tensile elongation at break. With slightly lower density, the new carbon fiber composite technology offers these unmatched advantages together with further lightweighting possibilities. Major customers seeking to improve the impact and cold impact performance of carbon fiber composite applications are already evaluating the added potential for weight reductions, lower material and energy consumption, associated cost savings and reduced environmental impact.
Xecarb ST thermoplastic composites are based on selected polyamide matrix materials – PA66, PA6, PA11, PA12, PA6.10, PA6.12 and PA4.10 – addressing different mechanical, thermal and physical requirements. Standard carbon fiber content is 30 percent (CF30). The PA6-based composites are also available as CF20, CF25, CF35 and CF40 grades. In addition, the portfolio includes two high-modulus materials for enhanced flexural strength, and provides a wide engineering window for further customization depending on specific application needs.
Xenia Thermoplastic Specialties launches new range of supertough carbon fiber composites.
“Beyond winter and mountain sports equipment from boots and running shoes to bikes, these new high-impact carbon fiber composites will help us reach into other markets and further expand our customer base in Europe, APAC and North America,” adds Enrico Mancinetti, Sales Manager. “Driving this growth, Xenia Materials will also increase its European sales force with a strong focus on qualified local customer support and service.”
Covestro and Sol Kohlensäure Sign Framework Agreement for Biogenic Carbon Dioxide (CO2)
Covestro’s NRW sites supplied with biogenic CO2 from SOL Kohlensäure
Supply partnership helps Covestro switch to alternative raw materials
Both partners advancing Circular Economy and climate neutrality
Materials manufacturer Covestro and SOL Kohlensäure GmbH & Co. KG have concluded a framework agreement for a supply partnership for biogenic carbon dioxide (CO2). With immediate effect, SOL, as one of the most important European suppliers of gases and gas services, will supply the liquefied gas to Covestro sites in North Rhine-Westphalia, where it will be used to produce plastics such as MDI (methylene diphenyl diisocyanate) and polycarbonate. Under the terms of the framework agreement, SOL Kohlensäure will already supply up to 1,000 metric tons of biogenic CO2 this year. From 2023, the supply volume is to be further increased substantially, enabling Covestro to save the same amount of CO2 from fossil sources at its NRW sites.
“We have set ourselves the goal to become fully circular. To this end, we want to convert our raw material base to 100% renewable sources. We are very pleased to have found a partner in SOL Kohlensäure who will support us in this transformation with a pioneering spirit,” explains Daniel Koch, Head of NRW Plants at Covestro.
“We at SOL Kohlensäure are advancing the shift to more sustainable CO2 sources. In this way, we are increasing security of supply, becoming independent of fossil raw materials, and reducing our environmental footprint at the same time,” emphasizes Falko Probst, Sales Manager at SOL Kohlensäure.
Inspection and acceptance of the delivery, from left to right: Katharina Rudel, Chemical Technician Covestro; Marcus Ney, Plant Manager Covestro; René Theisejans, Production Expert Covestro.
From waste product to raw material
The CO2 used is obtained by SOL Kohlensäure from various sources, such as bioethanol and biogas plants. In these plants, CO2 is produced as a by-product during the treatment of various biomasses, such as plant residues. This is separated by SOL Carbon Dioxide, purified and then made available to Covestro production as a raw material.
In this way, the supply partnership supports the circular concept and contributes to reducing emissions.
Covestro’s Lower Rhine sites in Leverkusen, Dormagen and Krefeld-Uerdingen are ISCC Plus certified and can supply their customers with more sustainable products made from renewable raw materials.
Biogenic gas being delivered, Luis Da Poca (SOL) connects the tank.
Goal of climate neutrality by 2035
Covestro has set itself the goal of becoming fully circular. This also includes using alternative raw materials. Biomass, CO2, as well as end-of-life materials and waste replace fossil raw materials such as crude oil or natural gas. Carbon is managed in a circular way. In realizing these ambitions, both companies are relying on long-term supply partnerships.
In addition to biogenic CO2, Covestro is investigating the use of other technical gases from renewable sources. The materials manufacturer is already offering its customers its first sustainable products, such as climate-neutral¹ MDI. With the expansion of its alternative raw material base, this portfolio is set to grow further in the coming years.
ISCC (“International Sustainability and Carbon Certification”) is an internationally recognized system for the sustainability certification of biomass and bioenergy, among others. The standard applies to all stages of the value chain and is recognized worldwide. ISCC Plus also encompasses other certification options for instance for technical-chemical applications, such as plastics from biomass.
Climate neutrality is the result of an internal assessment of a partial product life cycle from raw material extraction (cradle) to the factory gate (Covestro gate), also known as cradle-to-gate assessment. The methodology of our life cycle assessment, which has been critically reviewed by TÜV Rheinland, is based on ISO standards 14040 and 14044. The calculation takes into account biogenic carbon sequestration based on compensation measures.
Circular Economy in the Spotlight: AST Group Uses Lindner Plastics Recycling Technology to Close the Loop
Since 2018, the AST Group, producer of HDPE plastic containers and drums, has been committed to cleaning and reconditioning used containers to ensure a longer service life for its products and greater sustainability in the production process. Since 2021, the loop has been closed by another piece – a plastics recycling facility (PRF)
from Lindner has been processing post-consumer containers, which are then used to produce new drums and containers. As these products are also destined for the hazardous and foods industries, high-quality recyclate is crucial as are optimally coordinated recycling processes.
Circular economy, the Green Deal, recycling quotas, resource conservation, energy efficiency, sustainability – these are the buzzwords we hear each and every day, especially in the recycling industry. After all, our industry is essentially about responsibly managing our environment and its resources as well as the associated effort to retain materials in the economic system at the highest quality and for as long as possible. As a production company, the focus is on product design, durability, recyclability and, in particular in the plastics processing industry, the quality of the recyclate used to manufacture the end product.
Centre of competence for sustainable product manufacturing The AST Group, in particular the parent company AST Kunststoffverarbeitung GmbH in Erndtebrück, Germany, has been focusing on the circular economy and recycling for some time. Family-run, AST Group is one of Europe’s market leaders when it comes to producing plastic containers for the chemical and food sectors – industries in which high-quality plastic containers and bottles are crucial. From the beginning, the focus was on creating the optimum production loop that would make it possible to increase the recyclate quota for the company’s own products and also use the products made of recyclate in the hazardous and food industries. The stakes were unquestionably high. Nevertheless, a short while later, the first centre of competence for plastics was established and a complete plastics recycling line was installed to process post-industrial and post-consumer HDPE (high density polyethylene). This solution not only significantly contributes to the circular economy, it also ensures the internal supply of raw materials.
Energy efficiency and quality When it came to the recycling facility, the decision was made in favour of the Austrian industry pioneer Lindner. ‘It was important to us that the facility could process all kinds of materials, from hollow objects to regrind,’explains Hauke Grabau, Head of the Recycling Division at AST nststoffverarbeitung GmbH. ‘When designing the facility, we focused closely on energy-efficient technology that conserves resources. Shredders, mills, various washing steps – including the hot-wash system, which we can switch on depending on the required intensity – are perfectly matched to our requirements,’ says Grabau. Harald Hoffmann, Managing Director of Lindner Washtech, Lindner’s subsidiary specialising in plastics recycling, elaborates: ‘The focus during planning was on efficiency and high quality. Thanks to our modular system, the individual components can be ideally adapted to the input material and the degree of contamination. The efficient design with optimal bypass solution also makes it possible to process several material streams.’
The output material is characterised by a particularly high level of homogeneity and purity, which is perfect for subsequent extrusion. As one of only a few recycling specialists, Lindner offers complete solutions, optimally matching the individual process steps of shredding, sorting, washing and drying. ‘We are very pleased and will choose Lindner’s recycling facilities every time. A great team with highly motivated employees, with whom we enjoy a close working relationship,’ says Hauke Grabau.
New Plastics Recycling Facility Hauke Grabau, Head of the Recycling Division at AST Kunststoffverarbeitung GmbH, in front of the Lindner plastics recycling line. In his hands: one of the many AST containers produced with recycled granulate.
Lindner Hot Wash Depending on the level of contamination, the Lindner hot-wash system can be switched on flexibly. Specifically
designed to clean heavily contaminated plastics – the temperature in the washing process ranges from 50 to 85 °C.
Europe’s Largest Advanced Recycling Facility in Germany
Dow the world’s leading materials science company, and Mura Technology, the global pioneer of an advanced plastic recycling solution, today announce the next step in their ongoing collaboration to help solve the global plastics waste issue and advance circularity. Mura plans to construct a new facility at Dow’s Böhlen site in Germany – the latest in a series of planned facilities across the U.S. and Europeto rapidly scale advanced recycling of plastics – and the first expected to be based at a Dow site. This project is targeted for a final investment decision by the end of 2023.
Mura’s new Böhlen facility in Germany, which is expected to be operational by 2025, would deliver approximately 120 kilotons per annum (KTA) of advanced recycling capacity at full run-rate. This and the other planned units expected to be constructed across Europe and the U.S. would collectively add as much as 600KTA of advanced recycling capacity by 2030 – and position Dow to become the largest consumer of circular feedstock for polyethylene production globally.
“The continuation and growth of Dow and Mura’s collaboration is another example of how Dow is working strategically to expand and build momentum around securing circular feedstocks and supporting breakthrough advanced recycling technologies,” said Isam Shomaly, Dow business vice president for Feedstocks and Commodities.
“We continue to increase Dow’s capacity to use recycled content as feedstock, and continue to invest in the most effective technology available to enable our circular business model for plastics,” said Diego Donoso, president of Dow Packaging & Specialty Plastics. “The diversification of our feedstock slate and decarbonization of our assets will enable the achievement of Dow’s goal of a sustainable, low-carbon future, and meet strong and growing customer demand for circular polymers. This will be a significant step forward to decrease our dependency on virgin fossil-based feedstocks.”
The planned facility builds on Dow’s ongoing collaboration with Mura, first announced in 2021, with an initial project to construct the world’s first plant using Mura’s Hydro PRS process, located in Teesside, UK, which is expected be operational in 2023 with an initial 20KTA production line. The Böhlen, Germany, site, expected to be co-located with Dow’s manufacturing facilities, would enable a significantly larger capacity for plastic waste and considerably increase the supply of fully circular feedstock to the industry. This circular feed, derived from plastic waste currently destined for incineration or landfill, would reduce reliance on virgin fossil-based feedstocks and would enable Dow to produce a recycled plastic which is in high demand from global brands, particularly for high-end sensitive markets like food and medical applications.
Dow aims to take advantage of co-location benefits, which could significantly reduce the cost of scaling advance recycling facilities. In addition, co-location of Mura’s facilities at Dow locations would be expected to reduce carbon emissions by minimizing transportation of the offtake and as gas output from the advanced recycling process can be converted back to plastics, thereby ensuring no by-products go to waste.
Steve Mahon, chief executive officer at Mura Technology, said, “Combating the global plastics crisis requires innovative solutions which can drive a circular economy. Mura’s collaboration with Dow has led to the largest commitment across the industry to date, showcasing the urgency from industry leaders to adopt scalable solutions such as HydroPRS that will transform the plastics industry worldwide. Dow’s continued support for Mura Technology has led to a highly financeable commercial arrangement and the deepening collaboration will allow both companies to achieve their stated ambitions in the advanced recycling space.
“Dow’s commitments to accelerating a global circular plastics economy is exemplified through deploying Hydro PRSTM at the newest advanced recycling facility in Germany, which will enable us to dramatically increase recycling capacity. Through our collaboration and Dow’s extensive global reach, we can accelerate the pace and scale at which a circular plastics economy becomes a reality worldwide.”
Mura’s Hydro PRS (Hydrothermal Plastic Recycling Solution) advanced recycling process is unique, as it uses supercritical steam to convert most forms of plastics – including flexible and multi-layer plastics, which have previously been deemed ‘unrecyclable’ – back into the original oils and chemicals from which they were made. These can then be used to create new, virgin-equivalent plastic products which are even suitable for food contact packaging.
With Mura’s process, the same material can be recycled repeatedly, meaning it has the potential to eliminate single use plastic and prevent it from going to landfill or being incinerated. This has additional carbon benefits, with advanced recycling processes expected to save approximately 1.5 tons of carbon dioxide per ton of plastic recycled, compared to incineration and reducing reliance on fossil-based feedstocks.
On Presents the First Ever Shoe Made From Carbon Emissions
Swiss Sports Brand Creates Supply Chain Coalition to Reshape Carbon Waste Into Running Shoes.
Swiss sports brand On presents the first shoe made from carbon emissions, called Cloudprime. This is a significant moment in On’s journey to move away from petroleum-based resources by creating a new foam material called CleanCloud, made using carbon emissions as a raw material. On is the first company in the footwear industry to explore carbon emissions as a primary raw material for a shoe’s midsole, specifically EVA (ethylene vinyl acetate) foam, that could also be used in other shoe parts and products in the future.
On’s ambitions are high: The sports brand born in the Swiss Alps envisions a future where every On product is fossil free and fully circular. CleanCloud is the result of five years of dedicated work, which began with finding the best possible partners. This collaborative approach is key to overcoming the challenges of developing this complex technology at a commercial scale.
“Holding the first-ever shoe made of carbon emissions in my hands is a huge milestone – not only for On, but for the whole sports industry”, explains Caspar Coppetti, Co-Founder and Executive Co-Chairman of On. “Five years ago, this was barely a dream. Imagine what can happen in the future as we unlock the potential of alternative carbon sources with further research and in collaboration with the best partners.”
CleanCloud is the result of a pioneering supply chain partnership with some of the most innovative companies in biochemicals, process and material innovation, including LanzaTech, Borealis and Technip Energies. LanzaTech is using a combination of cutting-edge genetic engineering, state-of-the-art biotechnology, artificial intelligence, and innovations in mechanical and chemical engineering to manufacture chemicals using a process that soaks up waste carbon rather than emitting it.
“Today we continue our journey to show the world that recycled carbon is a resource rather than a liability,” says Jennifer Holmgren, CEO of LanzaTech. “As we increasingly convert pollution into the products we use in our daily lives, we will reduce the need to extract more carbon from the ground! The partnership between On, Borealis,Technip and LanzaTech will change how the world thinks about sourcing carbon, enabling us to bend the carbon curve, keep our skies blue, and create a sustainable future for all.”
Technip Energies is a leading engineering and technology company for the energy transition and in this consortium in charge of the process of dehydrating ethanol to the gas ethylene, which is a monomer and the most important building block of widely used plastics.
Bhaskar Patel, SVP Sustainable Fuels, Chemicals & Circularity at Technip Energies: “Technip Energies is proud to be supporting On in this exciting project to make CleanCloud a reality. The application of our Hummingbird technology to produce bio-ethylene is one step to a more sustainable future. We look forward to working with the On team to scale up and help bring CleanCloud to the world.”
Borealis is a leading provider of advanced, circular and renewable plastic solutions and essential in creating high-performance, easy-to-process EVA foam for CleanCloud. This collaboration clearly underlines Borealis’ commitment to a net zero future and fully aligns with its EverMinds ambition of accelerating circularity through partnerships.
Lucrèce Foufopoulos, Borealis Executive Vice President Polyolefins, Circularity and Innovation & Technology: “Borealis is thrilled to be part of this unique value chain collaboration. With our creative partners On, LanzaTech, and Technip Energies we are proud to co-create circularity in carbon and decouple plastic from its reliance on fossil-based resources. Through innovation and collaboration, we continue re-inventing essentials for sustainable living.”
This is how it works: Technology from LanzaTech captures carbon monoxide emitted from industrial sources like steel mills before being released into the atmosphere. Once captured, these emissions enter a patented fermentation process. Thanks to specially selected and naturally occurring bacteria, the carbon rich gas ferments naturally and is converted to ethanol. This natural fermentation process is similar to that of conventional alcohol production – e.g., beer brewing. The ethanol is then dehydrated to create ethylene by Technip Energies, which is then polymerized by Borealis to become EVA (ethylene vinyl acetate) in a form of solid small plastic pellets – the versatile and lightweight material that On starts working with to create a performance foam for shoes.
On’s ambition is to bring the CleanCloud technology to as many consumers as possible in the near future. “We believe that On can be an agent for positive change through enabling and accelerating the scale up of sustainable technologies such as CleanCloud”, says Caspar Coppetti.
Driven by the same spirit of sustainable innovation, On is collaborating with circular start-up Novoloop on the CleanCloud outsole, by utilizing the world’s first chemically upcycled TPU from post-consumer plastic waste. The outsole was put under rigorous lab and athlete testing, meeting specifications comparable to fossil derived TPUs with a significant carbon footprint reduction. For the upper, On is collaborating with the young French start-up Fairbrics to create a polyester-based textile made from carbon emissions.
Southeast Asia’s Largest High-Quality & Food-Grade Recycled Plastic Resin Plant
PTT Global Chemical Public Company Limited (GC) has long been committed to building greater balance and sustainability for the future, with the ultimate aim of achieving Net Zero, or reducing greenhouse gas emissions across all operations to zero, by revolutionizing the use of circular resources. To this end, GC is proud to partner with Alpla Co., Ltd. to introduce Envicco into our portfolio, The largest plastic resin plant in Southeast Asia to manufacture world-class high-quality and food-grade recycled plastic pellets. This plastic recycling plant, located at the Asia Industrial Estate in Map Ta Phut, Rayong, Thailand, will reduce the amount of domestically used plastics in Thailand by 60,000 tons/year, while decreasing greenhouse gases by 75,000 tons of carbon dioxide, equivalent to reforesting 78,000 rai of forest or more than 8,000,000 large trees.
Dr. Kongkrapan Intrajang, Chief Executive Officer, PTT Global Chemical Public Company Limited, said: “As the world’s leading chemical company, GC has integrated the circular economy concept into their operations and business model to optimize the use of resources in order to improve the global quality of life, reduce climate impacts, and create global sustainability and balance. Today, GC is proud to reveal that Envicco is ready for commercial operation. Used plastics within the Kingdom of Thailand will make up 100% of the raw materials processed by Envicco’s cutting-edge production technologies to transform used plastics into valuable products. These end products will hold equal quality and be nearly indistinguishable to brand new ones. The Envicco production plant is part of our long-term circular economy strategy to fully realize GC’s value chain. It also has the added benefit of creating jobs within the community while simultaneously aligning with the Thai government’s BCG Model (Bio-Circular-Green Economy Model).”
Gunther Lehner, Chairman of Alpla Company Limited, said: “Envicco is one of the fastest built facilities in history. Thanks to our invaluable partnership with GC, this facility now stands at the forefront of our industry and will definitely play an important part in Alpla’s recycling business in Asia.”
Envicco is a world-class facility, equipped and operated to international production standards, manufacturing high-quality and food-grade recycled plastic resins that are certified by the US Food and Drug Administration (US FDA). The facility features state-of-the-art European technologies and quality control systems throughout the manufacturing process, resulting in consistently high-quality and safe products for consumers. Envicco Limited is the joint venture between GC and Alpla, the world’s leader in plastic and recycled plastic containers. Both companies are fully committed in preserving the value of plastics as much as possible.
The newly built plant has a maximum production capacity of 45,000 tons of recycled plastic resins each year, which can be divided into 30,000 tons of rPET resin and 15,000 tons of rHDPE resin. Envicco operations will reduce plastic waste by 60,000 tons per year and reduce greenhouse gas by 75,000 tons of carbon dioxide, equivalent to reforestation of 78,000 rai or planting 8.32 million large trees.
In addition, GC has also partnered with various organizations to educate the public on waste management and separation through many projects, including Upcycling the Oceans, Thailand, Think Cycle Bank, and PPP Rayong. Recently, GC also established the youturn platform – a comprehensive used plastic management platform, in accordance with circular economy principles, that supports gathering, separating, and transporting used plastics to be recycled into lifestyle products at the Envicco plant. This scalable platform is easily accessible, fits everyone’s lifestyles, encourages waste separation, contributes towards the country’s greenhouse gas emission reduction targets, and ultimately helps us create a better world for the next generations to come. Together To Net Zero.
Black Plastics Recycling: Towards a Circular Economy
Black plastics have been notoriously difficult to detect, but recent technological developments have made it possible to sort them not only by color but also by polymer, unlocking economic value for recycling companies. This is a game changer in the fast-evolving plastic packaging sector, and Stadler – a leading supplier of sorting plants for the recycling industry – is experiencing an increase in the demand for systems capable of recovering all black plastics from the waste stream. Through effective collaboration among all players in the industry’s value chain, a financially and environmentally beneficial circular economy is possible.
Plastic packaging serves important functions in modern life, and we have come to rely on it heavily. It is an exceptional product that, however, has a significant end-of-life problem. This is especially true of black plastic, which until very recently couldn’t be detected with the available technology, Near Infrared (NIR). “The emitter shines a light on the material and the sensor takes a reading of the energy that is reflected back,” says Enrico Siewert, Director of Product and Market Development at STADLER. “However, carbon black absorbs the light, so the signal doesn’t bounce back and the sensor doesn’t get a reading. This means that black plastic is undetectable with the technology that is widely deployed in the recycling infrastructure.”
Why recovering black plastics matters
Black plastic makes up a significant part of household waste which, if not recovered, will be incinerated or sent to landfill. This has not only environmental implications but also financial, as Enrico Siewert explains: “If recycling companies can’t recover black plastics, they can be losing as much as 15% of the value of their inbound material. When they are able to mine this material out of the waste stream, they can create economic value and positively impact their bottom line.”
Various clean plastic containers for take away or delivery food
“Another important consideration is that more and more packaging is made of black plastic, as more recycled content is used. When recycling post-consumer packaging, if it’s not rigorously sorted by color, the resulting output is a grey resin. This can’t be taken back to white, so many converters add carbon black to obtain a very uniform, more appealing color. We, as a society, want more recycled content, we will see more and more black material in the waste stream. Consequently, packaging will continue to trend towards a darker color.”
A game-changing technological development
Different industries involved in the plastics value chain have been researching solutions to the black plastics issue, and today there are different ways of recovering these materials. A first solution is a sensor-based dry sorting system, which uses NIR sensors with detectable black additives to detect the different types of polymers. There are also other types of sensors capable of sorting black materials, also by polymer. With this sensor-based dry sorting system, it is possible to accurately sort black polyethylene, polypropylene, PET and polystyrene.
Another solution is a wet density sorting system based on the flotation principle. The ligher polyethylene and polypropylene float, while the heavier PET, PVC and plystyrene tend to sink. The drawback of this system is that, not only is it costly due to the filtration process, the need for water, cleaning, etc., it is not capable of sorting by polymer, so that a circular process is impossible.
“However, the biggest advancement has been in sensor technology,” states Enrico Siewert. “The situation has evolved to the point that today we are able to separate black not only by color but also by polymer. This is very important because if the sorter ejects all black materials together, there could be as many as 15 different polymers in the mix, which can’t easily be remanufactured.”
“This is a very recent development: 5-6 years for black color detection and polymer sorting. This is a true game changer because it creates economic value and makes it possible to recycle these materials that would otherwise go to landfill or incineration.”
New opportunities for contributing to a circular economy
The ability to detect black plastics means that there will be more of them in the recycling chain. “We have to create a demand for these post-consumer black materials. Obviously, there are limitations: they can’t be used to produce white products, and they can’t always make food-grade packaging. We have to collaborate across the industry value chain to find other ways to use black plastics. It won’t necessarily be for consumer-facing products, but they could be used to manufacture items such as pallets, buckets or railroad ties, etc. It’s about sorting the plastic effectively and providing it as a feedstock to the advanced recycling sector.”
Chemical recycling companies are an excellent example of operations that could make good use of these materials: “They are looking for polyethylene and they don’t care if it has black because they break it down into a gas and convert it into oil, which is transformed into virgin plastic – closing the loop of a circular economy.”
It is also important to extend this cross-industry collaboration to packaging designers and producers. “We need a conversation between manufacturers and recyclers where they address together considerations such as: does the consumer really need or want black packaging? If the material can’t be recovered, what matters the most to the consumer? Do they want a close loop solution for the package they buy, or do they care more about how it looks? Such an approach will help address the black plastic problem and get a better recovery of the waste stream.”
Black plastics processing: a demand set to continue to grow
The latest technological developments and the consumer pressure for more recycled content in packaging are bound to drive continued growth in demand for sorting plants capable of recovering all blacks out of the waste stream.
Stadler has experienced a sharp increase in the interest in these solutions and it is at the heart of this evolution in the industry: “We now have multiple partners that have developed technology to detect black plastics, so we have the ability to design systems to recover these materials tailored to our individual customers’ operational requirements and capital investment,” says Enrico Siewert. “We have completed several projects for some of the most advanced light packaging recycling plants in Europe, and we are working to develop many more.”
“The demand is extremely strong for this technology, and I see this trend continuing in the future. More black plastic is going into the waste stream and the technology to mine these materials is catching up fast,” concludes Enrico Siewert.
New Plastics Recycling Facility Hauke Grabau, Head of the Recycling Division at AST Kunststoffverarbeitung GmbH, in front of the Lindner plastics recycling line. In his hands: one of the many AST containers produced with recycled granulate.
