TAGS: Sustainability and Bioplastics
When it comes to recycled plastics, compounders, and processors confront major challenges particularly with regard to Post Consumer Recyclate (PCR) in terms of broad variances in:
- melt flow,
- discoloration,
- heat degradation, and
- most importantly contamination.
The goal here is always to manufacture high-quality plastic parts that will require recycled content resins and compatibilizer additives.
This preceding approach will work even better with Post Industrial Recyclate (PIR), especially where materials are sourced from closely monitored in-house regrind or strictly controlled end-of-life converted plastic goods collected as waste. So, how can we create a circular economy in a critical, technologically challenging, public attention-grabbing, flexible packaging segment?
Since its inception in 2017 European industry group CEFLEX is bringing together a broad and inclusive, 180-member, range of stakeholders representing the entire flexible packaging value chain that includes plastic, paper, and aluminum foil raw material suppliers, coating and adhesive producers, film and flexible packaging manufacturers, end-use brand owners, recycle and waste management firms, technology companies, and extended producer responsibility groups. CEFLEX is focused on four key enablers namely:
- Materials, package design, and markets,
- Capacity for sorting and recycling,
- Extended producer responsibility (EPR) systems tailored to the complexity of flexible packaging, and
- Fostering a supportive legislative framework.
Full circularity is scheduled for implementation in 2025.
CEFLEX’s Strategic Framework for a European-wide Flexible Packaging Circular Economy
(Source: CEFLEX)
Moving forward, plastic sorting technology is advancing rapidly. Yet delivering 100% pure streams based on traditionally defined polymer resins in post-consumer recycling facilities still remains a distant goal. The picture becomes a little better with post-industrial waste. For example, it remains difficult to separate polyethylenes from polypropylenes, not to mention the near impossible untying of multilayer barrier films.
Thus, currently, there are numerous recycle mixes that are composed of incompatible plastic materials. Yet the global plastics industry is charging ahead with better than historical 30% + average recycle mix content usage, and advances in compatibilizing additives to upcycle these same widely varying blends.
Industry Faces Challenges to Achieve a Scalable Adoption of PCR and PIR Plastics
Let’s focus on reviewing two recycled plastic materials, one process, and two application innovations respectively.
ELIX Polymers & Partners' ABS Resin from Sustainable Acrylonitrile Monomer
To start with, well-established, Spain-based ELIX Polymers has commercialized its
E-LOOP Acrylonitrile Butadiene Styrene (ABS) intermediate performance level plastic resin that has been developed from a sustainable acrylonitrile monomer. ELIX has done this through a novel partnership with AnQore, a specialty Netherlands-based chemical supplier of an International Sustainability & Carbon Certification (ISCC) Plus certified acrylonitrile monomer.
- The monomer is produced from non-fossil fuel-based feedstocks namely propylene and ammonia.
- It has a 60% lower carbon footprint as compared to the traditionally used, existing materials.
In turn, AnQore’s acrylonitrile monomer, referred to as Econitrile, is produced from sustainable bio-naphtha and bio-gas supplied by the Netherlands’ OCI-Nitrogen.
ELIX Polymers' Circular Economy E-LOOP ABS Partners with AnQore and OCI
(Source: ELIX Polymers, AnQore, and OCI-Nitrogen)
Kraton’s Compatibilizers Increase Post-consumer Recycled Content
Next,
Kraton’s CirKular+™ C1000, C2000, and C3000 compatibilizer additives product line was specifically designed to address three critical unmet plastic industry challenges namely:
- end-of-life plastic product recyclability,
- inferior Post-Consumer Recyclate (PCR) quality, and
- limited reusability of mixed plastic waste.
The CirKular+™ C1000 compatibilizer grades are block copolymers derived from PolyStyrene (PS), PolyEthylene (PE), and Butylene Rubber (IIR), which is a copolymer of isobutylene with isoprene. They are multi-plastic resins compatible with:
- PolyPropylene (PP), High-Density PolyEthylene (HDPE), and other polyolefins,
- PolyStyrene (PS) and High Impact PolyStyrene (HIPS),
- highly polar materials such as PolyEthylene Terephthalate (PET), PolyAmides (PA, or Nylon),
- bioplastics like PolyLactic Acid (PLA), and
- wood plastic composites.
Kraton’s CirKular+™ C2000 and C3000 similar to the CirKular+™ C1000 compatibilizer act as impact modifiers within polyolefin matrixes and increase Post-Consumer Recyclate (PCR) content at 5% loading levels. Additionally, CirKular+™ C2000 and C3000 compatibilizers can be used in high-value end-use applications, with up to 25% recycled content, regardless of preceding defined mixed polymer combinations.
Compounded PCR HDPE, PCR PET, and Kraton’s CirKular+™ C1010/1000 Compatibilizers' Benchmarking
(Source: Kraton)
Kraton's CirKular+™ compatibilizer additives are RecyClass approved by tests established by the U.S.-based, Association of Plastic Recyclers (APR), and are in conformity with similarly defined European recycling standards, particularly with regard to broadly mixed plastics packaging waste. CirKular+™ technology employs a holistic retail collection approach to the end-product lifecycle across a broad range of applications.
Kraton’s CirKular+ Closed-loop Infant Car Seat and Suitcase Retailer Collection Programs
(Source: iStock)
Carbios' Enzymatic Recycling Process for PET Molded Plastics
Continuing, let’s transition from recycling materials to our single recycling process. France-based Carbios is developing a unique recycling process using an enzyme very capable of depolymerizing PolyEthylene Terephthalate (PET) molded plastics and textile fabrics. Carbios has built a world-first demonstration plant that operates on a batch basis converting 2,000 kilograms at more than 95% yields with 10-to-20-hour production runs. The short-term goal is to move quickly towards 100% yields, as Carbios constructs its first
50,000-ton capacity production plant in partnership with Indorama Ventures, a global leading, Thailand-based, sustainable chemicals company.
Starting six years ago Carbios and France’s L’Oréal, a global personal care products market leader, cofounded an industry consortium to commercialize enzymatic depolymerizing
PET recycling technology that now includes major packaging brands such as Nestlé Waters, PepsiCo, and Suntory Beverage & Food Europe, along with textile market leaders comprised of Patagonia, On, Puma, and Salomon.
Carbios Depolymerizing PET Enzymes (L), Lab Process (C), Demonstration Plant (R)
(Source: Carbios)
Solvay's Recycled PARA Compounds to be Used in Automotive Applications
Delving further, let’s conclude by reviewing two plastic recycling applications. Solvay has started a circular economy effort where it is working with the France-based surgical equipment start-up supplier, Ostium Group to mechanically recycle their high-temperature performance PolyARylAmide (PARA) resin used in stainless-steel replacing, lighter weight, medical application. This allows medical facilities to reduce:
- sterilization time,
- cost and disposal, and
- lowering the carbon footprint.
Ostium will supply hospitals with new custom-designed surgical kits, and collect these instruments after use. Solvay's recycled
Ixef® PARA compounds maintain 85% of flexural properties with no loss in outstanding surface appearance, as compared to virgin grades. With stringent healthcare regulations precluding reuse, Solvay will redirect recycled PARA materials to automotive and recreation equipment markets.
Solvay’s PARA Surgical Instrument Partnership with Ostium Group
(Source: Solvay)
LANXESS' Glass-fiber Reinforced PA for Reduced Carbon Footprint
Finally, application-wise, LANXESS has commercialized a Durethan® Blue PolyAmide 6 (PA 6, or Nylon) BKV50 compound that is 60% ECO glass-fiber reinforced and reduces the carbon footprint of an
Electric Vehicle (EV) battery charger cover by 46%, as compared to a traditional PA 66 with conventional glass fiber reinforcement. Together with the 60% ECO glass fiber and other PA 6 resin renewable content, more than 90% of the compound has sustainable alternatives. Lastly, the carbon footprint of ECO glass fiber is 66% less than conventional glass fiber.
LANXESS’ PA 6 ECO Glass-reinforced Compound EV Battery Charger Cover (Black)
(Source: LANXESS)
Recent Innovation Updates in Plastic Recycling Materials & Technologies
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successful plastics recycling system by clearly understanding the recovery & reuse model and gaining in-depth knowledge about advanced technologies, materials & applications. Also, learn how ocean-bound PET bottles are used in a feed stream for chemical upcycling into PBT resin, reactive recycling improves the performance of mixed recycled polymer streams that are difficult to recycle, and more!
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