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For a long time, chemical recycling was considered an unfinished addition to established material processes. In the meantime, however, some technologies are making the leap into large-scale industrial use: an overview of the various processes and providers.

Overview of the Various Processes and Suppliers

Recycling

Kunststoff Werkstoffe

Polypropylen

Polyurethan

Kunststoff

Kunststoff-Recycling

What Is Happening in Chemical Recycling?

With Newcycling, multi-polymer and multi-layer plastic packaging, that previously could not be recycled, can now be separated and processed into homogeneous regrind using ZSK twin screw extruders.

APK Relies on Newcycling Processes

Polyethylen

Polyamide

Extruder

Extrusionsanlagen für KU-Verarbeitung

How to Make Plastic Compounds out of Packaging Waste

Milliken PP additive for thermoforming uses cleaner chemistry to deliver brighter look.

Warmformen / Thermoformen

Polypropylen-Compound

Additive

New PP Additive for Thermoforming Food-Contact Applications

 Husky Injection Molding Systems Ltd., Bolton, Ontario/Canada, has launched its new NexPET system – a mid-volume PET preform molding solution purpose-built to help producers introduce multiple new applications into the market more quickly and cost-effectively than ever before.

Spritzgießen

Spritzgießmaschinen

 A Solution to Accommodate Niche Brands

The joining of dissimilar materials is a special challenge for joining technology. Thermal direct joining together with suitable surface treatments enables stable joints between very dissimilar materials combinations, thus offering an alternative to classic procedures for joining hybrid parts.

Thermal Direct Joining of Plastic-Metal Combinations for Industrial Applications

Aluminium

Laserstrukturieren

Verbindungstechnik, hybride

Alternatives to Gluing and  Mechanical Joining

The non fossil fuel-based portfolio offers same high quality and performance for applications in all industries.

Gehäuse aus Kunststoff

Polystyrol

Kunststoff-Aufbereitung

Standardkunststoffe

Kunststoff-Regenerate

Kunststofffasern

Borealis Launches Portfolio of Circular Polyolefins

The availability of PET bottle flake outside the beverage sector is expected to decline continuously in the coming years. Tray-to-tray recycling can close this gap and succeeds particularly easily with a new extruder.

Polyester

Blasfolienextrusion

Flachfolien- und Plattenextrusion

Polyethylenterephthalat

Folien

Kunststoff-Rezyklat

Unique PET Tray-to-Tray Recycling in a Single Extrusion Step

Twin-screw extruders enable even contaminated post-consumer polystyrene to be depolymerized continuously and efficiently. This opens up a promising recycling route in terms of industrial implementation via renewed polymer synthesis to produce plastic granules with a quality approaching that of virgin material.

A Robust Continuous Process for the Chemical Recycling of Polystyrene

Extrusionsanlagen

Turning Old into New

Simultaneous extrusion of polyvinyl chloride profiles with a PS foam core is challenging due to the different processing conditions and has not been performed before. A trial plant for researching this process has now been set up at the SKZ.

Method for the Simultaneous Extrusion of Window Profiles with a Foam Core

Schaumstoffe und Vorprodukte

PVC-Profile

Schaumstoffe

Polyvinylchlorid

Dichtungsschäumen

Rohr- und Profilextrusion

Foamed and Still Extruded  in One Step

The Danish company Plastix recycles old fishing nets and ropes. The granules produced are used by JSP International, among others, to manufacture expanded polypropylene (EPP).

Expanded Polypropylene from Maritime Plastic Waste

From Fishing Net to Particle Foam

Styrenics can be polymerized using different technologies and it can be modified with a range of copolymers. The resulting plastics offer a wide range of properties allowing to customize them for different applications. Because of this range of properties they are suitable for many industries. Strong demand is for example driven by the automotive industry, healthcare and the packaging industry.

Styrenic Polymers

Verpackungsmaterial

Automotive

Technische Kunststoffe

Styrol-Copolymerisate

Medizintechnik

Medizinprodukte

Diverse Shapes and Applications

Because of its good temperature resistance, impact resistance and aesthetics appearance, acrylonitrile-butadiene-styrene is often used in household goods and in the automotive industry. The development of a circular economy also shows successes.

Acrylonitrile-Butadiene-Styrene (ABS)

Elektronik

ABS / ASA-Kunststoffe

Sustainable Growth

In recent years, society’s view of plastics has shifted. The actual material advantages have been overshadowed by the plastics waste debate. Uncommon times, such as the Covid-19 pandemic, remind society of the outstanding contribution of plastics materials. Polyethylene is particularly strong in medical and hygiene applications.

Polyethylene (PE)

Strong in Medicine and  Sanitary Applications

Contrary to the current perception, plastics, as a component of packaging materials, often represent the most environmentally sound option. The plastics industry is currently undergoing a transformation, shifting the focus onto the realization of closed material loops as well as reducing the resource input with highly efficient materials.

More Resource-Efficient Materials for Thermoforming

Blend

Masterbatches

Resisting the Pressure

The goal of the European Union (EU) to recycle all plastic packaging in Europe in an economically viable manner by 2030 is exerting enormous pressure on the packaging industry. It is very common that packaging films are made of different materials, and this causes challenges since they are often not easy to recycle.

Designing Food and Consumer Packaging for Recyclability

Verpackungstechnik

Can One Material Be Enough?

Batteries in electric vehicles must be specially protected to counter the risk of fires. Battery trays made from aluminum frequently offer insufficient protection.

Underbody Protection for Batteries in Electric Vehicles

Polypropylen-Platten

Glasfasern / -matten

Elektromobilität

Polypropylene Beats Aluminum

Weight reduction is one of the major requirements of automotive components. Regardless of the vehicles in which they are used. One of the lightest materials that can be considered is polypropylene (PP).

PP Compounds for Automotive Lightweight Construction

Easier to Reach the Destination

Currently, recyclates are in high demand, including the automotive industry. Previously, component suppliers had reservations about using recyclates in safety-related areas, because mechanical properties varied too widely. Now, materials producer JSP has developed an expanded polypropylene with 25 % recyclate content precisely for these application areas. But to ensure high quality, close cooperation with the recycling company is essential.

Circular Economy for Expanded Polypropylene (EPP)

Automotive Components  Made of Packaging

The aesthetically and mechanically outstanding properties of styrene polymers are extensively enhanced by different blending partners. New developments include weather-resistant grades, laser surface structuring and fiber reinforcement. The newly founded “Styrenics Circular Solutions” industry association recently started a chemical recycling initiative for polystyrene.

Polystyrene and Copolymers Combine Aesthetics with Technical and Sustainable Properties

Polystyrol-Platten

Styrene Copolymers

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.

Continuing on a Growth Trajectory

Weichmacher

PVC-Additive

Granulat, PVC- (Compound)

PVC-Pulvermischungen

PVC-weich (Compounds)

PVC-Pasten

Schlagfestmacher für PVC

Polyvinyl Chloride (PVC)

In the midterm, a worldwide increase in PU consumption of 4 to 5 % per year is to be expected. Growth drivers are the sound economic performance in the major industrialized nations so far, and in particular the increasing prosperity in China and emerging markets. In future, the PU business will be strongly influenced by digitalization and the development of closed material life cycles.

The Global PU Sales Reached a New Record in 2018 with just over 20 Million Tons

Polyurethan-Schaumstoffe (PUR)

Polyurethane (PU)

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.

Growth through Sustainability and Technical Specialization

Polypropylene (PP)

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.

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

Polyethylen, ultrahoch-molekulares

Polyethylen-Platten

Polyethylen-Halbzeug

Besides compounds modified for special applications and lightweight components, sustainable materials are also becoming an increasingly important focus. In the additives sector, too, recyclates, the circular economy, and reprocessing are now playing a key role.