Plastics as the Trailblazer of Environmental Protection?

Are you already green, bio and sustainable? Ultimately, companies, politicians and private individuals are all trying to show how environmentally conscious they are. Or at least what plans they have in store for this. However, it is often more difficult to put them into practice than appears at first sight. The clean electric car turns out to be a CO2 monster guzzling up electricity generated by burning lignite. Or plastic, allegedly such a heavy polluter, turns out to be the option with the lowest carbon footprint in many areas.

For the plastics industry, this complexity is both a curse and an opportunity. Faced with very emotional images, such as turtles swimming in garbage, it is difficult to put across the material’s advantages. On the other hand, plastic can also contribute to making products and applications more environmentally friendly, for example by saving weight. So far, the packaging industry has been the butt of the criticism. For applications in technical equipment or as a construction material, plastic is not seen as a problem on the whole. In these fields, there are not many serious alternatives.

For packaging manufacturers, this is naturally cold comfort. There are proposals for greener packaging from many material manufacturers. You can gain an idea in our “Plastics World Market” Special, from page 10. But these proposals too, are certainly not easy to put into practice. If the changeover succeeds, however, and the industry manages to set up a functioning and comprehensive circular economy, it could emerge as the trailblazer in responsible management of raw materials. And who knows whether plastics might then serve as shining examples of environmental protection in a few years’ time?

Editorial Streifinger

Streifinger, Florian

The Future of Simulation: Questions and Answers at the Moldflow User Meeting “Connect!”

The injection molding simulation becomes more comprehensive and precise, starting with the material data up to the prediction accuracy. As this year’s Moldflow User Meeting has shown, Autodesk Moldflow can link with more and more CAD programs, significantly increasing the benefits of predictive results.

The injection molding simulation becomes more comprehensive and precise, starting with the material data up to the prediction accuracy. As this year’s Moldflow User Meeting has shown, Autodesk Moldflow can link with more and more CAD programs, significantly increasing the benefits of predictive results. What does this mean for the simulation engineer? Dr. Franco Costa, Development Manager Autodesk Moldflow Simulation Codes, and Thomas Wittmann, Managing Director of PEG GmbH, Darmstadt, Germany, dare to look ahead.

The last presentation of the Moldflow User Meeting “Connect!” in Frankfurt Höchst, Germany, which was organized by MF Software GmbH, Darmstadt, Germany, at the beginning of June, traditionally belongs to Dr. Franco Costa. The title Senior Research Leader for Autodesk Moldflow Simulation Codes is adorning his business card. He did not only give a forecast, concerning the innovations of the upcoming releases, which will be improved thanks to users’ feedbacks at many points – such as tiger strip prediction, sink marks in 3D or API solver extensions – but also gave examples about the design of Moldflow in the Autodesk CAD environment with reference to the Fusion 360 system, which can be used in a cloud with an access to many different programs, without purchasing licenses and from any connected PC worldwide (see Interview page 8).

This fits in perfectly to the overview in the welcome speech, given by Seth A. Hindman, Senior Manager Product Strategy & Management at Autodesk, where he clarified, in what connection Autodesk will put the simulation in “World Class Manufacturing Solutions”. The name Moldflow is in the same line with companies such as Delcam (CAD/CAM software solutions for production), Magestic Systems (draping software for carbon structures) and Netfabb (software for additive manufacturing), to manage offering flexible solutions for future tasks with the help of networks.

André Hau of MF Software followed up on these remarks and listed the partner firms of the company in Darmstadt. Among others there are cooperation’s with e-Xstream engineering (Digimat), Trexel (MuCell), gom (component measurement), recently also with Beaumont Technologies (material tests, Therma-flo, MeltFlipper) and Volume Graphics (evaluation software for industrial computed tomography). Moldflow product manager Rahul Patil reveals the goal in his contribution “4th Industrial Revolution”: the cross-linking of all persons and programs involved in the product development process.

No other Moldflow user meeting before had shown to this extensiveness the scope of the development of the simulation software or which details can be considered and individualized, so that sometimes outside of the lectures arose the question of an “overview” or the “end of the flagpole”. During the breaks many participants sought direct contact with the cooperating companies. A total of 24 workshops in two rooms were offered parallel to 20 lectures; the decision was not always easy, although overlapping of topics was mostly avoided. In addition to foam injection molding, gas injection technology and the processing of glass fiber reinforced materials, the main topics were API interfaces, which played a role in three presentations.

Susanne Kugler from Robert Bosch GmbH demonstrated a self-generated solution how to use the Developer-Tool in the Solver API, to simplify the coupling of flow phenomenon and user-defined fiber orientation, in order to improve the prediction accuracy (Fig. 1). Paul Borger and Bartlomiej Piotrowski, BSH Hausgeräte GmbH, were more down-to-earth and used the application programming interface Synergy API to automatically manage Moldflow projects, also for archiving and evaluating large models for report generation. That could be a pioneer model.

The company Novo Nordisk will also find followers. Rasmus Knudsen has demonstrated remarkable success in the standardization of simulation projects, and this, as the heir of the “Moldflow veteran” Mogens Papsoe emphasized, is also necessary, considering the volume of the Danish medical supplier. He intends to increase the current number of 150 Moldflow analyses per month by a factor of 10 and reduce the simulations’ processing time from two days to two hours at an average (Fig. 2).

MF Software Managing Director Sven Theissen comments on this improvement in efficiency: “We used the Synergy API and created a program called ‘Gate and Go’, so that the designer can use Moldflow without having to run it”. The handling of the user interface is easy and fast to learn, but the highly productive software works in the background. “Standardization and automation produce democratization,” sums up Rasmus Knudsen with a beaming smile. This will be a path for the future of simulation engineers as well: comprehensive standardized processes on the one hand, and a few, but demanding developments for specialists on the other.

It is no wonder that with these experiences at the tenth event of the “Connect!” series during the private discussion sessions arose the following questions: How and who should use the higher performances and ancillary programs of Moldflow? More work for the simulation engineer? Or the designer? Can automated processes compensate or even minimize it? Can a specifically qualified staff take over a part of the work?

The topics at the eleventh User Meeting 2020 could respond the questions above. Sven Theissen has already got one of those answers: “In the Moldflow Academy, which our company recently launched, even experienced users can deepen their knowledge in specialist fields. PEG Managing Director Thomas Wittmann adds: “We are starting up a project of qualifying specialists, who will be able to understand complex tasks within the interconnected structure and the simulation and solve them in a team via the allocation of responsibilities. Thereby, the above-mentioned trend has reached Darmstadt as well: Autodesk CAD design and Moldflow simulation are growing together evermore.

“Due to global trade conflicts it is difficult to predict how fast design and simulation in plastic injection molding will develop. The market has not yet decided which companies whom and in what sector will employ, for example concerning the home office,” says Thomas Wittmann. However, there are also obvious positive trends, for example in automation. The Synergy API still offers many possibilities here. A prototype for report generator has just been developed and released for free testing, that can save up to 50 % of time.

“The initial feedback has been very positive”, says Wittmann and reveals another innovation: “Tolerance analysis parallel to the development “. This means an analysis that checks and evaluates all tolerances of a part already after the first simulation and before the mold. “One approaches the final mold in simulation steps and always has an eye on the tolerances,” summarizes Sven Theissen, admitting that he is looking forward to the feedback at the Düsseldorf K fair in Germany. And who is doing the job? The answer comes fast: “Everyone, whom the commissioning company sends to us for training”.

Fig. 1. More precision: Susanne Kugler from Bosch uses the Developer Tool in the Solver API to optimize prediction accuracy with the help of extensions 

Fig. 2. According to Rasmus Knudsen, product development at Novo Nordisk takes too long. He wants to drastically reduce simulation processing time with a new tool from MF Software 

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Heinz-Jürgen Rottig is a freelance journalist for plastics engineering topics.

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Renouncement is the trend that determines public perception of plastics today. Many consumers prefer products that are better for the environment, which is often equated to using less plastics. It is true, though, that plastics are important materials when it comes to finding answers to the challenges posed by the increase in population, high energy demand as well as growing urbanization and mobility.

Renouncement is the trend that determines public perception of plastics today. Many consumers prefer products that are better for the environment, which is often equated to using less plastics. It is true, though, that plastics are important materials when it comes to finding answers to the challenges posed by the increase in population, high energy demand as well as growing urbanization and mobility. And often they also represent the variant that has the least impact on climate.

Despite all critics, world plastics production has further grown over recent years. In 2018, it grew by 3 %, reaching almost 360 million t. Europe’s share in the market is approx. 17 %, making it the third largest production site. China has been the main “plastic nation” for some years now, with its global share of approx. 30  %, at present.

And this is part of the challenge that the material as well as the industry have to cope with: the booming industries of plastics and packaging, especially in South East Asia, have led to an ever-increasing waste problem. Scientists say that more than half the plastic waste that ends up in the oceans comes from five countries, i. e. China, Indonesia, the Philippines, Thailand and Vietnam. In many places in Europe, consumer plastics no longer go to landfills. Rather, they are reused, with some of the recycling rates even higher than 95 %. It will now have to be a major target to take the existing know-how to countries that lack behind in the area of plastics recycling.

„Plastics save energy, reduce emissions and they are resource-efficient“

This is where the K 2019 trade fair in October is going to give new dynamism and ideas, with one of the main topics being sustainable development and recyclability of plastics. Issues such as resource efficiency and climate change not only are omnipresent in political and social discussion, they are critical for plastics industry, too. Ways of efficient handling of energy and material, as well as establishing a closed-loop economy that manages resources efficiently, are more in demand and more important than ever. To reach this target, the entire service life of a product needs to be taken into account, which means the consequences of raw material generation, production, usage and disposal for the environment and society need to be equally included into the total balance.

The plastics slogan “less is more” shows its positive meaning here: thanks to properties such as low weight and durability, plastics are extraordinarily significant in order to reach the aims of saving energy, reduce emissions and use resources in a more efficient way, whether used in applications such as lightweight automotive construction, or as isolation materials for energy-saving buildings. Replacing plastics with other materials steps up energy and material consumption, in most cases, just as it increases CO2 emissions. Taking a constricted approach to the service lives and recyclability of products can therefore counteract the objectives of resource efficiency and climate protection. “Plastics shape the future” is the name of a special show presented in hall 6 at the K trade fair. This joint project of German plastics industry and Messe Düsseldorf will make a major contribution to achieve the named targets. Panel discussions and presentation will show how plastics are helping and will help to create a sustainable and resource efficient future for our planet.

Dr. Michael Zobel, Vice-President at PlasticsEurope Deutschland e. V. and Managing Director, High Performance Materials, at Lanxess Deutschland GmbH, Dormagen, Germany

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A PDF file of the article can be found at  <a href="http://www.kunststoffe-international.com/2019">www.kunststoffe-international.com/2019</a>–10

Read the German version of the article in our magazine  Kunststoffe or at <a href="http://www.kunststoffe.de">www.kunststoffe.de</a>

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For Decades, PE Has Been Improving Living Conditions in the Areas of Packaging Safety, Medical Technology, and Weight Reduction

This contribution has made PE the most commonly used plastic worldwide with current growth rates of 4 % and global consumption of 100 million t in 2018. While industry has in the past concentrated on the functional improvement of PE, the focus of development now is on sustainability, recycling, and reduction of CO2 emissions.

In considering global annual growth rates, one point is worth noting: even behind low single-digit percentages, lie substantial tonnages (Fig. 1). Modern world-scale production plants today have capacities of 400 to 500 kt/a. In other words, nearly ten such plants per year are needed to achieve an annual growth rate of 4 %. In this context, some seven new world-scale plants have been planned for the period 2018 to 2020. The region of the world’s largest PE demand  is currently Northeast Asia, dominated by China, followed by North America, and Western Europe (Fig. 2). Demand in Northeast Asia will further increase in the coming years, which will shift the relative weighting of sales regions over time. This region is growing much faster than North America and Europe with their more saturated markets. But, here, too, a look at HDPE demand shows a similar picture. The causes and consequences of this trend will be discussed in more detail in the following article.

Overall, PE continues to be the world’s most important and frequently used type of plastic: 38 % of all globally produced polymer materials are PE variants such as high-density PE (HDPE), low-density PE (LDPE), and linear low-density PE (LLDPE). This is likely to remain the case in the foreseeable future. In the coming years, PE demand will continue to grow at stable rates significantly above 3 % (Fig. 3). The strongest growth can be expected to be LLDPE with 5.1 % and HDPE with 4.6 % per annum by 2023. LDPE will lag somewhat behind with a growth rate of 3.4 %. This trend is also reflected in forecasts for the upcoming capacity developments. In the film and medical sectors, however, LDPE will remain a key material on account of its very good processability, transparency, and little or no use of catalysts, additives, and comonomers.

The trend just outlined is also evident in the ranking of the world’s largest PE producers (Table 1). ExxonMobil and Dow continue to head the rankings. The third-placed supplier follows at some distance and from then on the field is very close. Although some suppliers have changed places in comparison with 2016, the differences are far less than appear at first sight. What is without doubt noteworthy, on the other hand, is the large capacity increase of the US Chevron Phillips Chemical Company (CP-Chem). Since 2016, this Texan company has moved from tenth to first place in the HDPE producer rankings, although it is true that the capacities of the major HDPE producers are closer together than is the case for PE overall (Table 2). Capacity utilization of current PE production plants is good (around 90 %), with the exception of LLDPE capacity utilization (only 82 %). Up to 2023, the development of PE capacities will keep step with forecast demand.

Figure 4 shows which regional capacities are available worldwide to service the growing global demand for PE. It can be seen that Europe is moving at a slower pace than the other regions. In Europe, between 2015 and 2018, there was neither a capacity expansion nor were any appreciable capacities removed from the market. In the upcoming years, the status quo will continue to prevail in this respect. The focus on differentiated properties rather than large tonnages appears to be the main reason. This is the result of a trend in response to existing and future new cheaper capacities from the Middle East. European PE producers are turning away from making commodity plastics that cannot compete with those from plants that the new suppliers have built practically on top of their oil wells. Instead, they see opportunities in concentrating on specialties from smaller, very flexible plants with lower capacities. The trend towards higher-quality, long-lasting, ecofriendly PE products is also playing into the hands of the European producers.

In the Middle East, too, progress is surprisingly slow, as measured by the figures for the past six years. There, producers continue to rely on plants with high throughputs that can be operated with as few product changes as possible. Nevertheless, in the past three years, only weak growth has been recorded, which is not expected to accelerate in the upcoming years. The largest growth rates are expected to be in North America and China. In North America, growth in the last three years has been only moderate. But on the basis of the oil and gas reserves opened up in this continent by fracking, HDPE and LLDPE could see a quite considerable capacity expansion by 2023. The new capacities in the USA will be world-scale plants designed more for commodities, like those in the Middle East. An exception here is the new Hyperzone plant being built by LyondellBasell, which will also produce specialties. It is due to start up as planned by the end of 2019.

Feedstock Prices and Production Costs Dictate Choice of Production Site

Just like the Middle East, North America is benefiting very considerably from the price trend in PE raw materials. Currently, ethylene is being produced globally from ethane and naphtha in roughly equal proportions. The naphtha price follows the oil price and is correspondingly volatile, although fluctuations in the last three years have not been quite so massive as between 2013 und 2016. On the other hand, ethylene can be produced very economically in ethane crackers. By doing so, North America (with an ethylene price of 110 to 330 USD/t) has been largely able to catch up with the Middle East (60 to 130 USD/t) in terms of raw material costs. However, if new production plants are built in Europe and other countries reliant on naphtha, ethylene prices will be considerably higher. This fact means that many US-based oil and petrochemical companies are planning to invest in their home region rather than in a region at the other end of the world, additionally characterized by higher raw material costs or growing political instability.

Nevertheless, at the present time, some 60 % of all plants still date from the “naphtha era”. In the future, new plants are likely to operate only in regions with lower feedstock costs. The most notable exception to this is China, which is striving to increase its self-sufficiency to satisfy its huge and rapidly growing domestic demand.

China Is Changing from a Consumer  to a Producer

It is not only on account of its large population that China is an exciting market. The important growth formula here is “per capita consumption times demography”. The key lies in the number of households that can afford convenience products with PE packaging. In China, the number of these households long ago exceeded the 300 million mark, although the income gap between the rural and urban populations is still enormous. In a country with many cities of over a million inhabitants, the number of households belonging to the middle and upper income groups is increasing faster than in Western Europe and the USA. The pipe sector is currently showing particularly strong growth in Northeast Asia (2013 to 2018: 12.4 % per annum). On account of the growing number of high-income households, PE packaging is also increasingly in demand (films 2013 to 2018: 8.1 % per annum, blow molded products: 6.7 % per annum over the same period). Although growth is forecast to be somewhat weaker in the next ten years, the currently expected growth rates are still remarkable by global standards. Examples worth mentioning include pipes 2018 to 2028: 6.4 % per annum, films 5.1 % per annum over the same period (source: IHSM).

On the other hand, Africa and India, despite their rapidly growing populations, will remain in the shadow of the the far eastern giant for quite a while when it comes to PE consumption, even though the population of China by 2050 will not be increasing as quickly as that of the Indian sub-continent. Per capita consumption in India of around 4 kg still lags considerably behind that of Northeast Asia (about 19 kg) or even of western countries. The latter are expected to reach saturation point soon with a per capita consumption of 27 kg PE. Looking at the growth of higher- and middle-income households, China is some ten years ahead of India.

Another reason for the Chinese growth is the desire of the population gradually to reach the same living standard as the West. Polymer materials and packaging that keep goods fresh for longer represent positive achievements of the West. Associated with this is the aspiration to become self-sufficient in polyethylene in the foreseeable future. China would like to reduce its dependence on foreign suppliers in view of the ongoing trade war, particularly with the USA. As a result, frantic efforts can currently be seen to obtain the important raw material ethylene by alternative routes, for example by coal gasification.

Looking at global PE trade flows, this trend becomes even more apparent. North America is expected to significantly expand its role as a net exporter in the next decade. PE exports from the Middle East, on the other hand, will largely stagnate until the middle of the next decade and only start to rise again in the middle to end of the 2020s. It is also interesting to note that the Commonwealth of Independent States (CIS), consisting of ten states of the former Soviet Union, including Russia, is expected to become an exporter during this period.

Future trends in North America and the Middle East can be readily deduced from the analyses given above. Meanwhile, the most exciting development lies ahead in China. Northeast Asia will continue to import strongly, even if domestic PE production carries on rising. The PE quantities imported by China are expected to equal the complete export performance of the Middle East in numerical terms by 2028 – even if the exports from this region of the world naturally also go to other countries. It should be remembered, however, that China, as the “workbench of the west” does not purchase these gigantic quantities of plastics just for its own consumption.

As already forecast some years ago, global consumption of PE exceeded 100 million t for the first time in 2018 (Fig. 1). HDPE continued to account for the bulk of this, followed at considerable distance by LLDE and LDPE. The lion’s share of current PE production goes into the manufacture of films, followed by injection molding and blow molding applications. (Fig. 5). The highest growth, however, is recorded by the pipe sector. This can be seen very clearly in the range of HDPE applications shown here. HDPE can take more and more market shares away from conventional pipe materials such as concrete, cast iron, and steel. This is thanks to the increasing infrastructure demand in many countries, and by no means just in emerging nations, called on to provide new supply systems for an increasingly prosperous middle class. In developed countries, too, there is in some cases considerable pent-up demand for the renovation of existing systems.

The continuing trend towards economic trenchless pipe installation requires specialized PE materials that on the one hand have good long-term stability but on the other are sufficiently flexible not to be cracked by contact with sharp-edged stones. In earthquake-prone countries such as Japan, flexible pipes are also safer than rigid lines made from conventional cast iron or concrete. This challenge is met primarily by multimodal HDPE grades, which have now proved their worth in this application and have become established on the market. In these grades, polymers with different molecular weight and comonomer content are combined, giving rise to materials with property profiles that could not previously be obtained. This is made possible by progressive  synthesis in continuous series of stirred polymerization tanks, such as are used, for example, to produce Hostalen ACP from LyondellBasell or Mitsui CX from Mitsui Chemicals. Cascades of loop reactors also make this possible and produce bimodal plastics products, for example, Inovene S from Ineos or Advanced Dual Loop from Chevron Phillips Chemical.

The requirement specifications for PE pipes are being expanded at present and incorporated into the current standards. It can therefore be expected that PE will continue to grow in this market (Title figure). There is also rising demand for high-temperature materials for industrial applications and oil and gas pipe inliners. High-voltage lines, too, are becoming increasingly reliant on cable conduits that can withstand temperatures of around 70 °C long-term. This is, of course, still far below the melting point of the polymer but it is necessary to counter accelerated material aging at these temperatures. Improved long-term stability is achieved not only by suitable polymer variations but also through the intelligent use of additives.

There is also increasingly strong demand for PE pipe materials with higher stability to oxidative degradation. These are used primarily in Southern Europe, where drinking water is frequently treated with disinfectants because of the higher temperatures. Outside Europe, the trend towards larger pipe diameters is continuing. The drivers here include seawater desalination plants and pipelines for the oil and gas industry, which operate at ever higher throughputs. For these applications, the demand is primarily for materials with high melt strength that are processed on special internally cooled extruders.

In the automotive sector, HDPE is used, for example, in AdBlue tanks. The requirement here is for adequate low-temperature impact strength, which is ensured by multimodal PE grades. In some gasoline-powered vehicles, HDPE water tanks are expected to be used in the near future for the new water injection technology designed to reduce emissions from internal combustion engines (ICE). The batteries of electric vehicles will also benefit from semi-permeable membranes made of sintered, high-molecular-weight PE. At the present time, these batteries are still mainly produced in Asia but considerable capacities are also planned in Europe. However, these are not on a scale that could replace the quantities used for the much larger PE fuel tanks.

The quality of life of a sustainable society stands or falls by the production and supply of ecofriendly energy. PE is suitable here for use as a material for underground power cables. For this application, the requirement is not for commodity materials but for PE grades with high heat resistance and melting point. This is achieved, for example, by crosslinking. Similar requirements also apply to submarine cables, which can be cooled by the seawater. A high degree of purity is very important in cable materials. Even small impurities can give PE (normally an electrical non-conductor) low electrical conductivity, which can be problematic with the voltages in question. High-performance cables are needed not only for power transmission but also in power generation and storage, for example in large pumped-storage plants.

Glass fiber cables for data transmission are increasingly replacing copper lines. Here, too, the properties of flexible PE sheathing could be fully exploited long-term. For domestic connections to the digital network, pre-laid empty PE conduits in which lines are installed for their protection are of relevance. In the area of food safety and drinking water quality, the applicable regulations at EU level have been radically tightened. Most recently, the focus of the authorities has shifted to so-called non-intentionally added substances (NIAS), among other concerns. NIAS include, for example, catalyst residues and reaction and degradation products. This development was not foreseen three years ago. The new requirements now necessitate a whole series of costly tests and risk assessments.

The medical technology sector continues to demand high-purity materials. In addition, long-term security of supply is specified, generally with guaranteed formulation consistency over many years. If changes to the formulation are nevertheless unavoidable, for example as a result of new legal requirements, proficient change management is necessary. In the past, it was largely left up to suppliers to decide what special arrangements they made with their customers in such cases. This is about to change as a result of the new Medical Grade Plastics Guideline from the German Association of Engineers (VDI), which, after a long period of preparation, is being published in 2019. It specifies for the first time generally binding criteria for plastics in medical applications. This Guideline will make the market more transparent but at the same time stipulates increased product requirements, which some suppliers already fulfill, for example in the case of the Purell products from LyondellBasell.

The Classic Pyramid:  Reduce, Reuse, Recycle

Plastics packaging has its advantages, for example in terms of water consumption and fuel-efficient transport. Nevertheless, many PE producers are very actively developing more sustainable and recycling-friendly products to avoid waste. Among the measures being taken are material saving through downgauging and more effective polymer properties. It is not just in logistics that lightweight packaging offers an advantage but also in terms of recycling costs, which are often calculated on the basis of weight. This could open up a promising field of application for multimodal HDPE grades combining high rigidity with good stress cracking resistance. An example of a production process that makes it possible to unite such conflicting material requirements in a single material is the previously mentioned Hyperzone process. Another approach towards greater sustainability is that of single-material packaging for stand-up pouches. Besides mono- and bi-axially stretched PE, use is also being made here of new metallocene PE grades – some with higher density (stiffness) and other variants with lower density and very good toughness and sealing properties.

Single-material systems present quite a technical challenge because barrier layers are required to extend the shelf life of the packaged product. The solution could lie in specific mono- or bi-axial orientation of the PE polymer chains (BOPE, MDO PE), which improves the barrier properties of this polyolefin. This technology is not new but is gaining in importance. Further environmental protection measures will also impact on the future development of packaging materials. An example here is the EU Single-use Plastics Directive, which (among other things) aims at firmly attaching the lids of beverage containers. This is intended to prevent environmental pollution from discarded lids and closures. The respective materials can be recycled without any problem. Bottles made from polyethylene terephthalate are shredded so that the PE content can then be separated by flotation.

Mechanical and Chemical Recycling Are Gaining Importance

In 2018, some 2.5 million t PE were processed into recyclates in Europe, which represents a recycling rate of 18.2 %. Compared to 2016 (2.3 million t and a recycling rate of 17.3 %), this is only a slight increase but by 2022 some movement is expected (3.2 million t, 24.9 %). By 2030, Europe will pass the 40 % mark on present calculation. Currently, most PE recyclates go into the manufacture of refuse sacks (675 kt), various injection molding applications (500 kt), and construction and agricultural films (240 kt and 235 kt). In the next few years, increased use of recyclates is expected, especially in the blow molding sector (source: PlasticsEurope).

Whereas, just a few years ago, mechanical recycling was largely the preserve of smaller suppliers, now practically all major raw material producers have become very actively involved in this business – either in-house or through partnerships. Examples of this are the QCP joint venture between LyondellBasell and the recycling and recovery company Suez with PE materials for blow molding, the Borealis takeovers of recyclers mtm plastics and Ecoplast for blow molding and film materials, and the partnership between the petroleum products and energy company Versalis and the Italian recycler Montello. There is a wide product range and the material is suitable for a large number of applications. What has been and still remains a problem is the odor of the PE recyclates, which is reminiscent of detergents. This generally excludes their use in food packaging, for example, and the costly cleaning process to remove the odor is scarcely economic. The UK company Biffa supplies pellets produced from collected milk packaging. These and similar properties of PE recyclates are currently the subject of extensive research. The most important challenge for mechanical recycling is that many end applications require high safety standards that cannot be guaranteed with a mechanical recycling process (e. g. applications involving food contact or hygiene applications). The regulatory agencies must find the right balance here between consumer safety and mechanical recycling targets.

The industry is currently investing considerable sums in pyrolysis or gasification processes, which are grouped under the term “chemical or molecular recycling”. The aim is to increase recycling quotas by collecting waste fractions that cannot be recycled by more traditional recycling methods such as mechanical recycling. Among numerous examples in the industry is the cooperation between LyondellBasell and the Karlsruhe Institute of Technology as part of the MoReTec program. One of the main focuses here is on mixed or contaminated waste fractions. The production of synthesis gas by gasification or pyrolytic degradation in cracker-suitable oils as a naphtha replacement would open the door to a genuine loop, whereas mechanical recycling can often only offer downcycling. Chemical or feedstock recycling has the potential to give a decisive impetus towards a circular economy, since it fulfills the requirements for all current and future product applications. It is important, however, for the relevant waste legislation to leave the question of appropriate technologies open so that molecular recycling just like mechanical recycling can be counted in the material recycling quotas. Only in this way can it make its contribution to the circular economy.

The production and transport of PE raw materials and processed packaging materials create lower CO2 emissions than competing materials. Lifecycle analysis of PE in packaging shows an overall reduction in CO2 emissions compared to alternative materials and even compared to dispensing with packaging altogether. European PE producers are working hand in hand with other interest groups in the value chain, the legislators, and the regulatory agencies in Germany and other countries to ensure that reduction in CO2 emissions remains a priority for food packaging. This will be achieved by choosing the lightest packaging material and extending the shelf life of the packaged food products.

Another route that can be followed towards increased sustainability is with renewable resources. The demand for PE materials of this type has risen. A familiar example is the “I’m green PE” brand based on sugar cane from the Brazilian supplier Braskem. The use of organic waste as a cracker material is a further possible route. An example of this is the PE grade Circulen from LyondellBasell.

Patrik Schneider, Volker Lackner,  Peter Bisson, Bernd Marczinke,  all Frankfurt/Main, Germany, and

One of the most important applications for HDPE is impact-resistant pipelines. Here, durable polyethylene is replacing less reliable materials such as cast iron or concrete

Fig. 1. Global PE demand and average annual growth rates by 2023. For a growth rate of 4 %, nearly ten new world-scale production plants are required

Fig. 3. Global PE capacities in 2018, broken down by the most important variants. LDPE capacities will not rise so sharply. The greatest increase is forecast for HDPE

Fig. 4. Capacities of the most important PE grades by region (forecast for 2023 based on contracts already agreed). China, in particular, is expected to undergo almost explosive growth in the upcoming years

Fig. 5. Global PE demand by segment shows the growth in the pipes and profiles sector

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Polyethylen-Halbzeug

Growth through Sustainability and Technical Specialization

Higher mechanical properties with lower density make polypropylene an interesting alternative to polyethylene for a large number of applications. New catalysts and production processes offer a wider range of products. Monolayer films and recycling are under development. In the meantime, China consumes almost one-third of the PP produced worldwide.

With a global market volume of around 74 million t in 2018, polypropylene is the most widely used plastic in the world, in total surpassed only by the different types of polyethylene (PE, approx. 94 million t). Figure 1 gives an overview of the further breakdown of the global plastics market with its volume of around 300 million t per year. This is due not least to the vast range of types and applications, and the trend away from standard grades towards specialties for technical application fields is continuing. The average growth rate of around 5 % p. a. is higher than for other standard plastics. While the growth in Europe is slightly below 2 %, the market focus is clearly on Asia, and here in particular on China, which already today consumes almost one-third of the PP produced worldwide. By contrast with PE, however, the production volume is increasing more slowly than the consumption, and this could lead to supply shortages in the coming years [1]. As a result, the prices of PE and PP would appear to be gradually matching each other. What would appear at first sight to be good for the producers of polymers could, in the medium term, prove to be a disadvantage for them. The substitution of PP with other materials, in particular other polymers such as PE and polyethylene terephthalate (PET), could become attractive.

Apart from this cost-driven substitution, PP could also be substituted for other reasons. “Plastic” as a packaging material is regarded negatively by many consumers, and the search for alternatives has already begun. This should be seen in the plastics industry as an incentive to devote even more attention to topics such as sustainability and environmental protection. Despite the strong growth, the real market share of biopolymers is still only in the order of 1% . Of these, more than half are non-biologically degradable types, such as bio-PE or bio-PET. It is nevertheless important to remember that a return to traditional materials such as metal, glass or cardboard generally increases the weight and enlarges the CO2 footprint .

Catalyst + Process Technology = Product Diversity

Practically all PP suppliers emphasize the importance of matching production process and catalyst system. It defines not only the breadth of the possible product range, but also the productivity, process economy and the purity of the products with respect to emissions and catalyst residues. Of the catalysts, Ziegler-Natta types continue to dominate, where for example W. R. Grace & Co.-Conn., Columbia, MD/USA, offer Consista catalysts as an example of types without phthalates as internal donors [4]. At least in Europe, a complete changeover to these catalyst types appears to be in process; they are actively advertised, for example, also by Borealis AG, Vienna, Austria, and LyondellBasell Industries N. V., Rotterdam, Netherlands. In these times of globalization, other world regions can almost certainly be expected to follow. A global view of the polymerization processes being employed shows that the substitution of older plants is already well advanced. Bulk and hybrid processes, such as Spheripol and Spherizone from LyondellBasell or Borstar from Borealis account for around 53 % of the production volume, while pure gas phase processes such as Unipol from Grace or Novolen from Lummus account for roughly 44 % [5]. Slurry processes with solvents are still used for special purposes, such as high-purity products, but have only just 3 % market share.

In the field of material design, a new edition of the “Polypropylene Handbook” written by Prof. Karger-Kocsis who died in December last year has been published as a standard reference work [6]. The main aspects of the current structure and use of PP materials are presented here in ten chapters, starting from the influence of the polymer chain structure through to composites with fibers and fillers. Figure 2 shows an example from the chapter on copolymers in which the use of higher α-olefins such as butene and hexene as comonomers is also discussed. Newer catalysts, in particular metallocene types, will make this even more attractive. The diagram shows the differences in the development of the soluble contents with increasing comonomer content that represents a problem for the “normal” statistical copolymers with ethylene as it limits, for example, the use in the food sector.

Stand-up pouches (SUP) for foodstuff, pet food or detergents is one of the most rapidly growing PP applications of recent years. Due to their complex multi-layer structure, they are proving to be difficult to recycle. A solution here could be a changeover to a mono-material system with a combination of different PP-based materials. Figure 3 shows an example of a laminate comprising a biaxially oriented PP film (BOPP) and a cast film of PP. The advantage of this combination lies in the very good availability of BOPP, even with high-barrier properties, and the broad spectrum of properties of a PP cast film. The most important properties of PP include dimensional stability at high temperatures (sterilization, hot filling), mechanical strength (high rigidity with high toughness) and very low sealing temperatures.

Such mono-materials can generally only be produced, however, with special PP copolymers. Impact copolymers such as the transparent BC918CF or the extremely tough BD212CF (both from Borealis) are used for the mechanically most relevant main layer. A BOPP layer provides a very good water vapor barrier. Terpolymers such as TD315BF (Borealis) are used in the sealing layer in order to ensure high efficiency and leak-tightness of the packaging. PE plastomers such as Engage (Dow Chemical) or Queo (Borealis) enhance the toughness and extend the sealing window. They can be added in fractions of up to 10  % referred to the total structure without impairing the recycling. If a stronger oxygen and/or CO2 barrier is required, EVOHs can be added at rates of up to 5 % of the total weight or other barrier layers (preferably SiO2) can be employed. Such films are also suitable for other flexible packagings, such as tubular bags or lid films. “Design for Recycling” is definitely a current demand that should be laid down in codes of conduct [7]. Recycling thus starts at the beginning of the added-value chain and not only at the end.

Comfort is an important aspect with polymer fibers. PP types for the meltblown process with improved processability allow softer nonwovens to be produced (Fig. 4), also in the typical SMS (spunbonded/meltblown/spunbonded) constructions for hygiene or filtration applications. PP homopolymers with even higher melt flow index (MFI) than to date are now available, such as PP514M12 from Sabic and HL912FB from Borealis. Both products are based on phthalate-free catalysts and have low emissions; HL912FB can also be processed defect-free at higher temperatures.

Beverages and Medical Technology, Quick and Clean

A broad field of application for polypropylene are beverage closures, whereby the currently prevailing call for a permanent connection between bottle and closure will give preference to hinge-type closures (Fig . 5). The demands made on the material here, such as rigidity for stability and low material input, good impact resistance, resistance to shrinkage and short production cycle times can only be met using specially developed copolymers. Materials for beverage bottle closures of course also have to satisfy the requirements for food contact and for odor and taste neutrality. Here Borealis has brought a type onto the market with RF777MO combining the existing mechanical and organoleptic properties with improved flow properties (MFI 20) and the Borealis nucleation technology (BNT). The reduction in cycle time of up to 10 % lowers the processing temperature and energy consumption by up to 5 %. This special nucleation also results in dimensional stability, irrespective of the pigments employed. It is therefore a preferred material for use in flip-flop beverage bottle closures, but also in other food packagings, household goods and bottles (ISBM).

In the field of medical technology, the demands are also becoming increasingly complex, and apart from purity and sterilizability, also the precise reproduction of fine component details in injection molding is important. High-flowing copolymer types such as Bormed BJ868MO that combines an MFI of 70 g/10 min with high rigidity and impact strength extend the scope for special applications here, such as modern diagnostic systems (Fig. 6). For random copolymers with resistance to electron or gamma radiation used for sterilization, LyondellBasell has introduced a new product with improved flow properties in Purell RP375R. Transparency and low processing temperature simplify the application here.

Various Solutions for Lighter  Motor Vehicles

The automotive sector is going through a time of upheaval: new drive concepts and ever stricter emissions regulations are heightening the demand for lighter materials and components. In recent years, the percentage of mineral reinforcing agents has been reduced, and hence the material density lowered. At the same time, efforts have been made to reduce the wall thickness of the parts, an approach that calls for materials with better flow properties and higher rigidity, and hence normally with higher percentages of reinforcing agents. Increasing attention is also being turned, however, to thermoplastic foam injection molding in order to achieve not only good internal part properties, but also a high surface quality. The examples of the foam structure in Figure 7, however, show that in addition to the choice of polymer and the process design, great importance also has to be attached to the choice of blowing agent.

The interiors of modern cars are dominated by low-emission and odor-neutral polymer types with very high scratch resistance and surface quality. Modified polymers and lower filler content reduce weight and complexity, as illustrated by the new Skoda Scala (Fig. 8). Door panels, glove compartment, center console and instrument panel demonstrate the versatility of modern PP materials [8]. One of the main areas of concern for the exterior is an improved paintability. PP types such as PPC 8500 from Sabic and Daplen ED113AE from Borealis combine primer-less painting with high rigidity and low shrinkage. More complex part constructions and increasing numbers of integrated sensors (driver assistance systems and autonomous driving) necessitate materials with good flow properties and minimum coefficient of linear expansion. Apart from classic applications, such as bumpers, sills and spoilers, whole tailgate modules are being produced from PP in the meantime, with frame structures of long glass fiber-reinforced material and a painted outer skin of mineral-reinforced PP.

If an even higher elastic modulus is required, e. g. in order to substitute polyamide or metal, then glass fibers continue to be the standard for reinforcement. The Fibremod portfolio from Borealis extends up to 40 wt. % glass fiber for Fibremod GB477HP and even 50 wt. % for Fibremod GD577SF that is in widespread use, for example, for front-end modules. A combination with sheathed metal or organosheets based on woven long fibers can further increase the rigidity and generally replace metal and massively reduce component weight. Carbon fibers <a href="http://[9]">[9]</a> are to be preferred for high-end reinforcement that, for example for CB201SY, offer a modulus level of around 10,000 MPa. These materials enable modern electric cars such as the NIO ES8 (Fig. 9) to achieve greater ranges and better efficiency.

Foam molding is an important topic not only in the automotive sector, as evidenced by the success of the EcoCore process from Bockatech Ltd., Huntingdon, Great Britain, in cooperation with Borealis. This foam injection molding process allows particularly light and thermally stable products to be manufactured. The most important product is currently the re-usable “Corretto” coffee cup (Fig. 8) which, thanks to the use of 100 % PP as material, is also extremely easy to recycle. It is an inexpensive, break-proof alternative to the currently widely criticized disposable cups made from coated cardboard. In cooperation with Borealis, the types BH381MO (high-rigidity copolymer) and Daploy WB140HMS (long chain-branched homopolymer) were selected for production by foam injection molding that allows low material input and short process cycle times. Due to their high strength, packagings produced in this way are suitable for e. g. deposit and return systems that have proved to be successful with their recovery rates of up to 94 %.

Sustainability and recycling are becoming general necessities in the plastics industry. PP has good chances here thanks to its low specific energy consumption during production, low density and good long-term stability. Several leading manufacturers have recently launched initiatives for mechanical recycling. Total has taken over the French recycler Synova (20 kt/a), Borealis has built up a volume of 70 kt/a with the two companies mtm plastics, Niedergebra, Germany, and Ecoplast Kunststoffrecycling Ges.m.b.H, Wildon, Austria, and Lyondell-Basell and the Suez Group have completed the joint takeover of the Dutch plastics recycler Quality Circular Polymers (QCP) that processes plastic wastes into PE and PP reclaim.

A massive expansion of mechanical recycling as demanded by national and supra-national legislators [10], however, also necessitates significant growth in the fields of application of the materials thus produced. Here again, it is a question of convincing the ultimate user. Designers and processors also have to know that modern PP reclaim such as the new Borcycle MF1981SY is suitable for far more than just park benches. Recent plastic recycling figures show Europe to be on the right road, but with still significant differences between the member states [11].

Chemical recycling is also seen as a complementary solution [12] in order to no longer have to dump or incinerate in future. Here, for example, Sabic is working together with the British company Plastic Energy on the production of “Tacoil” as the basis for monomer production. Borealis is cooperating with the Austrian company OMV that is already producing raw material for the cracker on an expanded pilot plant for its ReOil process with a capacity of 100 kg per hour (Title figure). Other companies, such as Braskem, are employing in-house developments or, like LyondellBasell, are working together with research institutes. In the medium term, such processes could become a major source of raw materials.

Juliane Braun, Markus Gahleitner, Georg Grestenberger, Peter Niedersüss and Cornelia Tranninger, all Linz, Austria

[1] IHS Markit Chemical, Global PE/PP Market Outlook 2019

[2] Bioplastics market data 2018, online: www.european-bioplastics.org/market

[3] Franklin Associates, Life Cycle Impacts of Plastic Packaging Compared to Substitutes in the United States and Canada: Theoretical Substitution Analysis, 2018, online: https://plastics.americanchemistry.com/Reports-and-Publications/LCA-of-Plastic-Packaging-Compared-to-Substitutes.pdf

[4] Rego J.M., Kaarto J., Chou C.-J., The New Frontier of Z-N Catalyst Technology: CONSISTA™ catalyst, online: www.grace.com

[5] Nexant Inc., Polyolefins Technology Report, September 2018

[6] Karger-Kocsis J., Bárány T. (Ed.), Polypropylene Handbook: Morphology, Blends and Composites, Springer International, 2019

[7] Borealis AG, Polyolefin Packaging Design – 10 Codes of Conduct for Design for Recyclability, 2019, online: https://www.borealiseverminds.com/files/Polyolefin-Packaging-Design_10-codes-of-conduct_FINAL.pdf

[8] Kiener M., Schatz J., Dorfner W., Nowag M., Schott F., Licht E., Mahren G., Köhler R., Moderne Galionsfiguren, Kunststoffe 109 (2019) 3, pp. 60–62

[9] Pretschuh C., Steidl E., Müller N., Steinbichler G., Eine Kombination mit ungeahntem Potenzial, Kunststoffe 109 (2019) 3, pp. 103–106

[10] Adamy M., Geschlossener Kreislauf ?, Kunststoffe 108 (2018) 10, pp. 82–86

[11] Ragaert K., Delva L., Van Geem K., Mechanical and chemical recycling of solid plastic waste, Waste Management 69 (2017) pp. 24–58

[12] PlasticsEurope, Plastics – the Facts 2018, online: https://www.plasticseurope.org/application/files/6315/4510/9658/Plastics_the_facts_2018_AF_

The ReOil pilot plant at OMV AG in Schwechat, Austria, converts plastic wastes with poor recycling properties into cracker raw material, and hence into potential monomers

Fig. 1. Global production of different polymers 2018  (source: data from <a href="http://[1]">[1]</a> and other sources)

Fig. 2. Influence of type and volume of comonomers on the xylene-soluble contents of random copolymers (source: simplified representation from <a href="http://[4]">[4]</a>)

Fig. 5. The PP grade RF777MO is particularly suitable for flip-flop beverage bottle closures with hinge function due to its improved flow properties (© Borealis)

Fig. 7. Foam structure as the basis for mechanical strength and surface quality: finer cells are obtained through a modification of polymer and blowing agent (© Borealis)

Fig. 8. The interior of the new Skoda Scala unites various assemblies based on the same polymer concept, and always with low emissions (© Skoda Auto)

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Polypropylen-Platten

Polypropylen-Compound

Polypropylen

Global PVC demand has increased further. This is also forecast for the coming years. Besides product innovations, growth is mainly driven by infrastructure expansion. As a resource-efficient, durable and recyclable material, PVC could, in addition, benefit from growing environmental awareness.

According to the market research institute IHS Markit, the global production capacity for polyvinyl chloride (PVC) in 2018 was 55 million t. The biggest share of this, namely 54 %, is attributed to North East Asia. China, the biggest producer country, alone has 24 million t; North America provides 17 % of global capacity, and Western Europe some 11 % (Fig. 1). The highest growth rates in recent years can be seen in the USA and China. The USA, in particular, has an outstandingly good cost position thanks to its exploitation of shale gas, and exports around 37  % of its PVC production.

As in previous years, the manufacturers’ capacity ranking is led by Shin-Etsu Chemical, Tokyo. Westlake Chemical, Houston, TX/USA, with its European subsidiary Vinnolit, has advanced to second place, with Formosa Plastics, Taipei, Taiwan, following hard on its heels. In fourth place comes Inovyn, London, UK, which is part of the Ineos Group. Mexichem, Mexico City, comes fifth (Fig. 2).

In general, many of the major market players are originally from Asia. North America, too, is strongly represented. In terms of capacity, Inovyn is the only European raw materials manufacturer among the leaders. The picture looks entirely different for the research-intensive PVC specialties: with Vinnolit (which belongs to Westlake), Vestolit (part of Mexichem), Inovyn and Kem One, there are four European companies among the top ten specialties manufacturers (sources: IHS Markit/Vinnolit).

Overall global demand for PVC is growing. In 2018, it was 45.6 million t. The average growth from 2016 to 2018, according to IHS Markit, was 3.5 %. It was therefore 0.6 percentage points higher than from 2013 to 2015.

With a share of 45 % (+2), pipes and fittings were the biggest field of application by far. Rigid films and sheets also saw growth, with their share increasing by 1 to 18 %. In third place came profiles and hoses again, with 17 % (Fig. 3). The special field of paste applications makes up 6 % of total demand. Global PVC growth is supported by the developing economies in North and South-East Asia (demand in 2018: 47 and 6 % respectively) and India (demand in 2018: 8 %) (Fig. 4.). They are investing in expanding their infrastructure.

Large Differences in Per Capita Consumption

On average, the annual per capita consumption of PVC last year was 6 kg. In first place comes North East Asia, with 13 kg, followed by North America, with 12 kg, Western Europe, with 10 kg, and Central Europe, with 7 kg (Fig. 5). Global PVC trade continues to play an important role. In 2018, almost 10 million t were traded, according to IHS Markit. The biggest net PVC exporter in 2018 was North America, with 2.5 million t. It was closely followed by North East Asia, with 2.1 million t. Europe only plays an important role in the export of PVC specialties. The Indian subcontinent was the biggest net PVC importer last year, taking 2.2 million t.

The European PVC market recorded an average growth in demand of only 0.8 % from 2015 to 2018. The capacity of the European producers declined between 2013 and 2018. That led to increased utilization of the remaining plants. A comparatively high price level in Western Europe made imports more attractive. From 2016 to 2018, therefore, over 1 million t PVC was imported, mostly from North America. The average increase of imports to Western Europe in the period, at 1.3 % per year, was slightly above the average increase of exports, which was 1.2 % per year. However, Western Europe remains a net exporter (source: IHS Markit).

The prospects for the overall PVC market are generally positive – at least provided that the current trade tensions are resolved. The market researchers from IHS Markit expect that global demand for PVC will grow by an average of 3.5 % by 2023. It is thus significantly higher than the forecast global BIP growth of 2.1 % for this period. The strongest growth, at 6.8 %, is to be expected on the Indian subcontinent, followed by Africa, with 5.3 %, North East Asia, with 3.7 % and the Middle East, with 2.7 %. For Western Europe, primary PVC is expected to show a low growth rate of 0.8 %. One reason for this is the increasing use of PVC recyclates. In Central Europe, a growth of 2.9 % is forecast. The differences in demographic development will continue to be the main driver of regionally different growth in the future. Whereas, in many regions, the population is growing strongly, it is declining in the developed markets due to increasing aging.

In the future, the global growth of the PVC market will continue to be determined by the major global trends: a growing global middle class with high demands and living standards, increasing urbanization accompanied by high infrastructure needs, as well as more sustainable resource management and changing consumption behavior. PVC, as a resource-efficient, durable, safe and recyclable material – including in an increasingly circular economy – is well positioned here. In the long term, the market researchers from IHS Markit therefore forecast an overall higher trade volume of 2.4 million t until 2028 for PVC. First and foremost, North America will profit from this due to the advantageous cost situation resulting from shale gas. For 2028, it is expected that the USA will export up to 50 % of its production volume.

For the production of PVC articles, the traditional thermoplastic techniques of extrusion, calendering and injection molding will continue to predominate. Depending on the process and requirements, different suspension PVCs, as well as special grades, including high-molecular PVC, copolymers, emulsion-based processing aids and surface modifiers are used. They allow processing and end product properties to be modeled to a large extent.

Cables, e. g. for electromobility and autonomous driving, are subject to significantly changing demands on the sheathing. Ever more cable bundles and higher data volumes require high-performance cables that combine good heat dissipation with mechanical properties and good shielding.

Vinyl audio media are currently experiencing a renaissance; the global growth is estimated at 5 to 7 % annually. Suspension copolymers play a major role for the optimum impression during press molding, and the resulting sound quality.

Modern PVC window profiles are extremely weather resistant, dimensionally stable, easy care and available in various designs. Ever more complex profile geometries require better thermal insulation and more stable designs, which make metal reinforcements unnecessary, even for relatively large windows. Profile cores made from recyclate are increasingly being used. The post-coextrusion process allows seals to be durably bonded to the profile in one operation.

In the case of flexible products, such as tubes and gaskets, high-molecular S-PVC with a special grain morphology permits faster mixing with plasticizers. It also permits the more efficient absorption of alternative plasticizers that are more difficult to mix with PVC, and the absorption of significantly larger quantities. The latter possibility allows rubber-elastic properties to be achieved, which would otherwise be the reserve of elastomers. Recyclability, thermoplastic processability and the specific advantages of the material PVC, for example its chemical and weathering resistance, provide additional benefits.

Flooring: Combining Pastes with Thermoplastic Processing

In the flooring sector, luxury vinyl tiles (LVT) are becoming increasingly popular and gaining significant market shares compared to traditional floorings such as laminate. LVT products are available in a variety of designs, which can be freely combined, e. g. stone, wood, geometrical forms and with personalization for professionals, but also in the do-it-yourself product range. They are very resistant, scratch proof and easy care, show ever more delicate embossing, can be made to feel warm underfoot, and can even be laid in damp rooms. The design possibilities are becoming ever more versatile, for example paste technology can be combined with thermoplastic processing. In addition, more and more variations, for example with hard to soft carrier structures, click or bonded, as well as tiles or planks.

Besides standard processing by thermoplastic processes, particular PVC types can also be processed as liquids or pastes in the form of a plastisol. They are mixtures of paste PVC and plasticizers, with further formulation components such as fillers, stabilizers, biocides, pigments and additives. These PVC pastes are usually spread, dip or spray coated onto backings, such as paper, textile and metal, and gelled at elevated temperatures to form a film. In this manner, floor covering, special artificial leathers, tarpaulins, wall coverings or body seals can be produced. These are usually complex multilayer designs in which the main component PVC is crucially important for the processing and end-product properties.

Current trends in the field of wallpaper are, e. g. digital printing, for example for personalized designs, and embedded sensors or LEDs for active light management. In public rooms or health institutions, there is a demand for resistant, scratch-proof and easily washable compact wallpapers (anti-vandal treatment).