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Kisuma Gets Set to Tell the World About Landmark Sustainability and Product Innovation Progress at K 2022

Julie Fernandes
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Kisuma Gets Set to Tell the World About Landmark Sustainability and Product Innovation Progress at K 2022

Kisuma, the world’s largest producer of synthetic hydrotalcite, is gearing up to showcase an enormous array of sustainability progress and product diversification at the upcoming K 2022 show in Düsseldorf upstairs in Hall 7/A28.

The week-long event, starting on October 19, is the world’s leading business platform for the plastics and rubber industry. Stakeholders from around the world will converge to discuss key innovations, trends and challenges, as well as take the opportunity to forge new relationships and set out their visions for the future.

“Our organization has been historically low-profile about our contributions to customers, industries and most importantly to the global communities in which we service. Walking the walk is embedded in our culture. It’s our duty. We do it every day, pragmatically and proudly,” comments Marlus Ferretti, Chief Operating Officer at Kisuma Americas.

“The K 2022 has a particular significance to Kisuma, where many novel technologies and innovative solutions in polymer processing will be revealed. As per our legacy, we are not stepping out of character in big PR announcements. For that, we invite you to visit our booth at Hall 7 – level 1 – A28. Your time will be well spent.”

Kisuma’s K Show booth A28 in Hall 7.

This year marks the first time that Kisuma will have a booth at the K forum. It promises to be a bustling and busy week, the company arriving in Germany with many stories of progress to tell, as well as one or two hints at what lies ahead in the pipeline.

Making sustainable gains
One such story centers around decarbonizing heavy industry through carbon capture.
Since 2010, Kisuma has been heavily involved in a project led by a TNO-backed platform to develop Sorption Enhanced Water Gas Shift (SEWGS) technology – a solution which can be used for reactive separation of H2 and CO2 from syngas sources.

The company has been developing and producing the sorbent used in SEWGS, which is being successfully demonstrated on an industrial scale at Swedish Steel company SSAB. Its initial pilot project named STEPWISE, has been operating at a cyclic capacity of capturing 14 tons of CO2 per day, with plans to expand this by a multiple of five by 2024.

SEWGS will allow industries to eliminate hard-to-abate CO2 emissions and produce blue hydrogen at lower costs than previously possible. So far, we have demonstrated a 30% cost saving versus the next best carbon capture alternative, the highest purity of carbon capture (97.5%) and successful production of blue hydrogen at 400°C.

“Subject to further demonstrations at technology readiness level 8 across 2026 and 2027, we anticipate being ready to scale up to full commercialization by 2028,” added Tim Hauck, General Manager of Sales and Marketing at Kisuma. “We remain open to connecting with new partners on this project and welcome any conversations and enquiries at K 2022.”

In other developments, Kisuma is fulfilling a growing demand for tin stabilizer replacements with ALCAMIZER, an effective non-toxic acid scavenger for PVC that delivers numerous benefits such as reduced exposure to harmful substances, improved weathering and improved recyclability at end of service life.

Meanwhile, the company continues to make impressive energy efficiency strides across its production processes. Since beginning full operations in 1999, Kisuma has reduced CO2 emissions per ton of product by 55% – a period in which it has also doubled plant capacity.

Non-stop innovation
Additionally, the company has laid the foundations for future waves of innovation. It has just invested in a new, state-of-the-art R&D lab which will support the diversification of product portfolios based on market insights.

In June 2022, Kisuma opened a new facility dedicated to running pilot projects. Designed to bridge the gap between small laboratory testing and bringing products through to commercialization, it will be able to process small and medium batch sizes to validate and optimize product quality as production volumes scale.

On the product development side, DHT-4 is the trusted acid scavenger designed to replace conventional (often heavy metal based) scavengers in BOPE films.

“This is the strongest acid scavenger available on the market,” said Mathijs Preenen, Business Development Manager at Kisuma. “It irreversibly scavenges acidic catalyst residues through an innovative interlayer capturing process. “Replacing the traditional acid scavenger with DHT-4C allows converters and brand owners to achieve superior surface properties of their BOPE layer, leading to stronger metallization of the film and enhanced surface printing capability.”

Unveiling their newly upgraded R&D laboratory.

Crucially, DHT-4 also represents a fully recyclable solution, enabling customers to enhance their sustainability credentials by introducing completely circular BOPE film products to the market.

Looking ahead to a bright future
Kisuma will not be able to reveal everything at K 2022, however.

Some initiatives remain in development, including the company’s ongoing partnership building with academia and hospital networks to see how its products can be used in potential cancer treatments. Meanwhile, the company is lining up sizable investments into more plastic recycling solutions. Hauck commented: “We invite visitors to K 2022 to come and see us upstairs in Hall 7/A28 to learn more about our plans in these areas.

Kisuma’s K Show booth A28 in Hall 7.

“Whether it’s progress already made or exciting innovations and developments in the pipeline, Kisuma sees a lot of opportunities for the future. We will continue to serve our customers with reliable products that have stood the test of time, and we will also work on the next potentially game-changing solutions for worldwide problems. “We are in a solid position to move forward by investing in our brand, which includes finding the exceptional talent and resources we need to keep moving.”

 

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Safely Packaged: Recyclable Reusable Transport Box Protects the Environment and Sensitive Goods

Julie Fernandes
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Safely Packaged: Recyclable Reusable Transport Box Protects the Environment and Sensitive Goods

Interview with Prof. Rudolf Pfaendner, Head of the Plastics Research Department at the Fraunhofer Institute for Structural Durability and System Reliability LBF

Packaging materials are often not very sustainable. This is partly because they are only designed for single-use transport. Researchers in the Fraunhofer LBF’s Plastics department have taken this fact as an opportunity to develop an alternative. With their recyclable reusable transport solution for sensitive goods, the climate, the environment and resources can be protected.

Prof. Rudolf Pfaendner, Head of the Plastics Research Department at the Fraunhofer Institute for Structural Durability and System Reliability LBF.

Prof. Pfaendner, congratulations: together with the Darmstadt-based start-up Berges GbR, you and your colleagues have developed a fully recyclable reusable transport box. How did that come about?

Prof. Rudolf Pfaendner: Sustainability is one of our core topics at the Institute, namely sustainability in the entire development – from the design of the material to the design of the application to high-quality material recycling. The latter means developing a product whose first application is followed by a second, third and so on. The latter means developing a product whose first application is followed by a second, third, etc. application and which can be completely recycled at the end of its life cycle. The fact that it has become a transport box came about through an internal discussion about ordering goods on the internet. People who order on the internet still usually produce a lot of waste – for the yellow bin through cushioning material such as polystyrene flakes and bubble wrap, for the waste paper bin through the cardboard box and corrugated cardboard. This has to be better in view of the CO2 footprint, the need to save energy and the scarcity of raw materials, we thought to ourselves and started to develop a sustainable transport box with equally sustainable padding material.

How did you get there?

Pfaendner: For one thing, we were able to draw on our extensive experience with the entire range of plastics that exist today. On the other hand, there are properties that our product multiple transport box must necessarily achieve or have: mechanical properties, high durability and more. For example, we tested the durability of the outer shell of the box in the laboratory by accelerated ageing, the weather resistance by UV light tests. The air cushion, in turn, had to have a certain stability and also withstand stretching over several hundred percent. Many laboratory tests were necessary until we found the material of choice.

The innovative transport box with inflatable air cushion can be customised and fully recycled. Copyright: Fraunhofer LBF, Raapke

The development has been successful. What makes it stand out?

Pfaendner: Certainly above all that the transport box and the cushioning material inside are made of the same material. This is an ideal mono-material for recycling and the box can be recycled in one step. The material is HDPE – High Density Polyethylene, the commercially available standard material. However, the box and cushioning material could also be produced from PLA – the renewable raw material polylactic acid. But the industry is still closer to PE.

What was the biggest challenge?

The new transport box with inflatable inner cushion. Copyright: Fraunhofer LBF, Raapke

Pfaendner: The challenge was certainly to develop cushioning material in a sustainable form. We succeeded with the airbag. It is a re-inflatable air cushion that can be inflated to different degrees via a valve, for example with a compressed air gun, and then wraps itself protectively around the packaged goods. In this way, a wide variety of objects can be safely packed – from sensitive machine parts to works of art. Up to now, the latter have often been transported in boxes produced especially for one-time transport, which are also foamed. Not very environmentally friendly.

What is the next step in your development?

Pfaendner: The box already has utility model protection and a patent application. We have shown its technical possibilities and proved that it works. Now we are looking for a partner who will produce it in larger numbers and test it in practice. Logistics and shipping companies that pack things in different quantities and dimensions would be suitable. But what would probably be closest is someone who has to continuously move machine parts between company location A and company location B, for example.

And when the “end of life” of the transport boxes is approaching and they are no longer functional, do they then go into the yellow bin?

Pfaendner: Oh no, they are far too good for that! Ideally, their owners collect them until a few have been gathered, have them shredded as recyclate stream and make new boxes out of them. Properties such as durability may then have to be improved with additives. We know these and they can easily be added.

 

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Economical, Material-Efficient Blown Film Technology for Reduced Thickness Thermoforming Films

Julie Fernandes
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Economical, Material-Efficient Blown Film Technology for Reduced Thickness Thermoforming Films

K2022 will see Kuhne Anlagenbau GmbH for the first time exhibiting as a manufacturer of large-scale lines for producing simultaneously biaxially oriented thermoforming films using Triple Bubble technology. At a thickness of 80 to 120 µm, these films are only about half the thickness of conventional cast films used in this application, and there is no need to compromise on service characteristics either. The maximum achievable thermoforming ratio is 1:10. This means a reduction in material consumption and thus in the associated greenhouse gas emissions of some 50%. Thanks to optimized cooling rates, these large-scale lines can achieve throughputs of up to 2,000 kg/h or annual outputs of as high as over 15,000 tonnes per year, which means that they can match or even surpass the productivity and profitability of cast film lines. Inventory can also be reduced in downstream processing, while the distinctly lower energy consumption of thermoforming enables a further reduction in CO 2 footprint and very good machine processability is also ensured. For manufacturers and distributors, the reduced thickness of the films means lower extended producer responsibility (EPR) levies andassists compliance with the Circular Economy for Flexible Packaging (CEFLEX) sustainability guidelines drawn up by the flexible packaging value chain.

Typical applications for such multilayer films include shelf-life extending vacuum packaging for the transport and storage of large pieces of ham, meat or cheese. Generally based on PA, EVOH and PE, these films combine high transparency with good thermoforming characteristics and elevated puncture resistance. Kuhne Anlagenbau, which developed the Triple Bubble process in-house back in 1996, has perfected the system and can now offer processors access to the attractive combination of low film thicknesses with the high throughputs which can only be achieved with large-scale machinery. This means the economic advantages traditionally enjoyed by cast films over blown films in this area are a thing of the past.

Typical applications for thermoforming films produced using Kuhne’s Triple Bubble® process include transport packaging for large pieces of meat or cheese. lena_zajchikova
Typical applications for thermoforming films produced using Kuhne’s Triple Bubble process include transport packaging for large pieces of meat or cheese. lena_zajchikova

The Triple Bubble technology for manufacturing biaxially oriented blown films is named after the serial arrangement of three bubbles. In the first, the film is rapidly cooled using cold water quench technology. Kuhne has further optimized this process for the large-scale plants, so enabling the efficiency-enhancing increased cooling rates which very effectively prevent crystallization processes as a prerequisite for uniform stretching in the following, second stage. The high level of orientation at the molecular level achieved in this second stage significantly improves the films’ mechanical and barrier properties. Thermal relaxation in the third bubble serves to set the desired thermoforming behavior.

Kuhne Triple Bubble lines currently enable the production of films with up to 17 layers at widths of up to 3,000 mm double flat (6,000 mm film width) and an output of as high as over 2,000 kg/h. The systems are suitable for processing any conventional polymers such as PE, PP, PET, PA, EVOH, COC, EVA, EMA, ionomers etc. Thermoforming formulations which, depending on the weight of the packaged goods, contain well below 10% PA and EVOH, also permit a dramatic reduction in thickness and ensure easy, high-performance processing. Monomaterial solutions based on PET, PA, polyolefins and further polymers are also possible.

Kuhne will be showing models of implemented large-scale lines at its K2022 booth (Hall 17 / A41), which will give visitors an opportunity to familiarize themselves with Triple Bubble technology. As Kuhne’s CEO, Jürgen Schiffmann, explains: “Working with us gives customers considerably more than just on-spec and on-schedule delivery and installation of the Triple Bubble line. Our service also includes application-specific film formulation and tuning of process parameters. In our experience, this means that processors can start commercial production immediately without protracted optimization.”

 

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Capsules Growth is Slowing Down And Competition Intensifies in Aluminium

Julie Fernandes
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Capsules Growth is Slowing Down And Competition Intensifies in Aluminium

AMI has published its 4th authoritative report mapping the global Single Serve Capsules industry. The report aims to support the development of robust participation strategies by equipping industry players and investors with a comprehensive understanding of scale of potential for future development, growth dynamics per system, market drivers and competitive pressures.

Over 80 billion capsules were filled in 2022 globally, both aluminium and plastic formats. Single serve capsules are a dynamic market segment with a complex value chain. The changes in this industry are fast, and driven by growing sustainability pressures and end-of-life scenarios, brand positioning as well as organic consumption trends.

The context of 2020-2021 pandemic lockdowns boosted the demand for single serve capsules in Europe and North America. Both retail and online sales of capsules sharply increased, anecdotal industry feedback being 30-50% growth in lockdowns. Operationally, throughout the first 2 lockdowns filling was working at near capacity and in shifts to assure safety of personnel. Some SKUs were sold out, which was to do with prioritisation of lines and optimal operations to limit changeover times. The second half of 2021 and 2022 resembled more of a normal sales pattern, and the spikes in consumption had settled down. The growth is now largely slowing down.

Unlike previously, there was a significant volume increase for original capsules between 2020 and 2022. Nestlé has been managing its portfolio of products extremely well – increasing sales of Nespresso via the Starbucks brand, which was popular in conventional retail. Still, the share of compatible capsules is rising. The Nespresso compatibles include both private label (retailer own brand) and branded offering (L’Or, Café Royal, Dallmayr Capsa).

The compatibles’ need for differentiation resulted in capsule material and barrier spec adjustments, impacting positioning. To this end, L’Or was successfully relaunched in aluminium capsules in 2017. Given L’Or’s aluminium victory, post 2018 the market had gone through the process of dramatic transition from plastic to aluminium Nespresso compatibles.

The growth of aluminium was a result of both the organic growth of consumption of Nespresso and Nespresso compatible capsules buoyed by system rationalisation, but also by inter-material substitution trend away from high barrier plastics in particular. As previously experienced with plastic Nespresso compatibles, there is a current need for differentiation of aluminium compatibles. This can be delivered with aesthetics – not only a variety of lacquers, but also embossing, design features, pre-printed patterns, etc.

The aluminium opportunity had beckoned new entrants and the competition has intensified.

 

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Borealis and Vibac Offer More Sustainable, Bopp-Based Film for Food Packaging

Julie Fernandes
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Borealis and Vibac Offer More Sustainable, Bopp-Based Film for Food Packaging

  • Biaxially oriented polypropylene (BOPP) film produced using circular Bornewables made from second eneration renewable feedstock
  • Vibac’s “V-Fresh” packaging film designed for easy sorting and mechanical recycling
  • EverMinds-inspired collaboration significantly reduces the carbon footprint of flexible food packaging

Borealis, one of the world’s leading providers of advanced and sustainable polyolefin solutions and a European frontrunner in polyolefins recycling, and the Vibac Group, one of the leading companies in specialised biaxially oriented polypropylene (BOPP) applications, announce the development of new and more sustainable BOPP-based film for food applications. Vibac’s “V-Fresh” BOPP film is produced with a grade from the Bornewables portfolio of circular polyolefins derived entirely from waste and residue streams. Because it is designed for recycling (DfR), the packaging can be easily sorted in polypropylene (PP) waste streams for mechanical recycling, thus helping increase the recycling quotas of flexible packaging formats. As an example of co-operation in the spirit of EverMinds that
accelerates the move to plastics circularity, the V-Fresh film packaging will be on display at the Borealis K 2022 stand in October.

Joint development yields BOPP food packaging format with lower carbon footprint

Polypropylene (PP) is widely used in the flexible packaging industry thanks to its cost and resource efficiency. When used for food-safe packaging formats such as bags and pouches for e.g., salad, fresh products and cut vegetables, the protective properties of PP help extend the shelf life by retaining freshness and minimising unnecessary food waste. Film converters are also looking to improve the sustainability profile of their packaging film solutions.

To lower CO₂ emissions and help address the issue of climate change, converters can now rely on the grades in the Bornewables portfolio of circular polyolefins. Derived solely from waste and residue streams, Bornewables grades are drop-in solutions that offer the same performance properties as virgin PP, yet with a substantially lower carbon footprint. Converters can use the Bornewables on existing equipment without having to invest in new machinery. The newly developed, monomaterial BOPP film can be easily integrated into PP mechanical recycling streams, thus upping recycling quotas for flexible packaging formats.

“Together with Vibac, we have been able to develop yet another packaging solution that exemplifies our EverMinds ambition, which is advancing plastics circularity by way of innovation and value chain collaboration,” says Peter Voortmans, Borealis Global Commercial Director Consumer Products. “Offering high quality and cost-efficient alternatives to fossil-based feedstocks is what we mean by re-inventing essentials for more sustainable living.”

“The combination of our BOPP film expertise with the polyolefins and recycling know-how provided by Borealis enables us to satisfy consumer demand for more climate-friendly packaging,” says Alberto De Paoli, Vibac General Director. “At the same time, we can still deliver the safety, freshness, and top-notch organoleptic qualities shoppers have come to expect.”

K 2022 will take place from 19 to 26 October 2022 in Düsseldorf, Germany.

We invite you to “Innovate Collaborate Accelerate” together with us by visiting Borealis and Borouge in Hall 6 at Stand A43, where the new V-Fresh fresh salad pouch will be on display.

 

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Asahi Kasei Europe Becomes Member of Joint Blockchain Technology Pilot Project for ISCC Plus Certification

Julie Fernandes
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Asahi Kasei Europe Becomes Member of Joint Blockchain Technology Pilot Project for ISCC Plus Certification

In September 2022 Asahi Kasei Europe became member of a pioneering joint project on blockchain technology for the ISCC Plus certification. Led by the Dutch software provider Circularise and the Japanese trading company Marubeni, this project aims at enhancing the efficiency of the certification process and the integrity of the certified data.

In order to achieve its goal of becoming carbon neutral by 2050 and to contribute to a carbon-neutral society, the Asahi Kasei Group is currently enhancing activities around the utilization of bio-based and recyclable materials, as well as renewable energy sources. To ensure full reliability and transparency, the company is accelerating the certification of its more sustainable materials, also responding to the changing needs of the customers.

The ISCC Plus certification is one leading global certification scheme that links the supply chain from raw materials such as biomass feedstock and recycled materials to finished products through mass balance management. This helps to guarantee full transparency of the final products to the end user. With both reliability of the certification and efficiency of the certification process increasingly growing in importance, Asahi Kasei Europe decided to participate in abovementioned pilot project.

Akira Nishizawa, Managing Director of Asahi Kasei Europe, comments: “We aim to contribute to a sustainable society through our business. As a supplier of plastics, fibers, and synthetic rubber, the ISCC Plus mass balance certification is becoming more important for us to advance this strategy.”

Test results confirm confidentiality and reliability of blockchain technology

In addition to the project leader Circularise, ten companies across the entire supply chain participated in this project, including chemical manufacturers, trading companies, and consumer electronics manufacturers. The mass balance management of ISCC Plus certification was operated on Circularise’s software system, and the 10 companies conducted trial runs, testing the effectiveness of the system, as well as the material traceability and data verification.

The results of the trials confirmed that in addition to the system efficiency, the utilization of blockchain technology ensures full confidentiality in the data transmission process across the entire supply chain, appropriate mass balance management, and full data reliability.

Nishizawa concludes: “Many of our products are currently in the process of obtaining the ISCC Plus certification. This still takes much effort and time.” A more efficient certification process is needed to achieve a sustainable society, and we have found that digital technology can play a major role in this process.”

 

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Comexi Enters the Digital Printing Sector With Its New Digiflex Press

Julie Fernandes
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Comexi Enters the Digital Printing Sector With Its New Digiflex Press

The digital press will be the primary attraction at Comexi’s K 2022 booth

After nearly 70 years manufacturing capital goods for the flexible packaging converting industry, Comexi is taking a step forward: fully moving into digital technology. At K 2022, the company will present the Digiflex press, its first digital printing solution that enables the flexible packaging industry to meet the current needs of a changing and increasingly demanding market. The Digiflex will be the primary attraction at Comexi’s Messe booth, 4B31, in Düsseldorf (Germany). From 19th to 26th October, during daily demonstrations, attendees will have the opportunity to view the Digiflex press in operation.

“The Comexi Digiflex is the machine that currently offers preeminent digital printing of variable data, such as Datamatrix variable codes, QR codes, barcodes, alphanumeric text, as well asother numbering and marking applications with high quality requirements”, explains Pedro Jiménez, the digital technical sales director at Comexi, who also highlights that “it is a digital variable data print press that offers extremely high printing speed, superb quality results, as well as the highest level of performance and production. Digiflex is an all-in-one solution that includes the integration of the curing process, tension control, printing registration, corona treatment, and a video inspection system.”

Comexi’s new digital press uses low-migration inks that are suitable for food packaging printing; it offers excellent results in regard to quality tests (tape, ethanol, and scratch). The machine allows for the possibility of double-sided printing without treatment, as well as printing on pre-printed material. A a digital press, the Digiflex is an efficient solution due to its ability to reduce set-up times. It can reach a maximum speed of 220 m/min, reduce material waste, and improve lead time. Furthermore, the machine offers high printing quality with a resolution of up to 1200×1200 dpi, a minimum code size of 8×8 mm, as well as printing and registration consistency.

Different Codes with Unique Information

Using the Digiflex allows for the printing of variable data such as QR codes, DOT codes, alphanumeric text, variable information, numbering, barcodes, Datamatrix or images. Each printed code can be different and contain unique information, providing traceable material information, thus personalizing products according to the consumer’s needs, and protecting brands from counterfeiting. “The Digiflex codes tracks and traces each product, complying with legal requirements as well as contributing to the circular economy, serialization and security of the supply chain,” says Jiménez, who emphasizes that this machine not only “helps boost
customer awareness, brand loyalty, and feedback acquisition, but also enables the analysis of consumer behaviour. Finally, the Digiflex offers security, anti-counterfeiting, and authenticity solutions, which is highly valued by brand owners.”

Comexi participated with its Digiflex press in the R-Cycle project, led by the Reifenhäuser Group. The unique codes of the press machine identify the plastic type and performed production processes of each packaging unit, which makes recycling more appropriate and efficient.

 

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Contract of Board of Management Member Dr. Klaus Schäfer Extended

Julie Fernandes
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Contract of Board of Management Member Dr. Klaus Schäfer Extended

The Supervisory Board of Covestro has appointed Dr. Klaus Schäfer as a member of the Board of Management for an additional period of six months until the end of June 2023. In view of the major geopolitical uncertainties, the Supervisory Board had asked Klaus Schäfer to extend his contract, which would expire at the end of the year. Schäfer has been a member of the Covestro AG Board of Management since the company’s IPO in 2015. As Chief Technology Officer (CTO), Schäfer is responsible, among other things, for the corporate functions Process Technology, Engineering, Group Health, Safety & Environment and Group Procurement, and thus, also for the energy supply of all the company’s chemical production sites. Jointly, Klaus Schäfer and the Supervisory Board have agreed to extend his contract for the period from January 1, 2023, to June 30, 2023, to ensure personnel stability for Covestro in this challenging time for the energy policy market.

“We are very pleased that we were able to convince Klaus Schäfer to remain on the Covestro Board of Management beyond his planned tenure. The current geopolitical challenges pose major issues even for a company as resilient as Covestro. In these uncertain times, continuity is more important than ever. With Klaus Schäfer, we have in our ranks a proven expert on energy issues whose expertise we will benefit from during this time,” said Dr. Richard Pott, Chairman of the Supervisory Board of Covestro AG.

“In my more than thirty years of professional life, this industry has never faced greater challenges. For me, continuing to support Covestro in this situation, even against my original plans, is a matter of course,” said Klaus Schäfer. “I would like to thank the Supervisory Board for placing their trust in me, and I will do my utmost, together with all Covestro employees and my colleagues on the Board of Management, to guide the company safely through the coming months.”

 

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“The Demand for Recyclates is All Across the Board”

Julie Fernandes
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“The Demand for Recyclates is All Across the Board”

Interview with Martina Schmidt, Head of the Business Unit Recycling at Vecoplan AG

Ms. Schmidt, is the circular economy gaining momentum?
Yes, this great collaborative project has picked up enormous pace. The circular economy is now perceived very differently from just a few years ago. Everyone has understood that it’s not just about functional waste management, but that all players in the market need to take part. This begins with product design, continues with politics (keyword: recycling quota), and finishes with the end consumer. Today, people are aware that the entire value chain must take action if we are to fight climate change and protect the environment.

From which sector is Vecoplan seeing this additional, awareness-driven demand?
The demand is all across the board. It is not limited to certain sectors, because the entire plastics industry is undergoing changes. The main impetus stems from the recycling rate. The plastics industry has to come to terms with the fact that, in future, the product that is launched onto the market will contain recyclate as well as being recyclable itself. This development is being driven from both sides: both the producer and the customer are now looking for recycling concepts. The trend towards individual cycles will change everything in a sustainable manner.

What are the consequences?
The demand is high, but there are not enough recyclates to meet those demands. The situation is currently being exacerbated by the fact that large corporations are creating these closed loops themselves. They then know the products that are in the loop, they know the manufacturing process, and the remanufacturing process. They know how the product comes back from the customer and how they can recycle it within their own loop. So, a large amount of potential recyclate does not reach the market.

How can you counteract this?
Our customers are experiencing shortages of materials and rising prices. As an alternative, they are looking for other material streams of the same material that are also recyclable. In the polyolefin sector for example, these are big bags, filaments, yarns, non-wovens. These materials are available in sufficient quantities, but until now there has been no need to focus on them. This raises the question of where these material streams come from, what their mechanical and thermal characteristics are, and what process must be set up to recycle them. Through our decades of experience and expertise, we are capable of fully supporting our customers in this field.

Can post-consumer plastics also be used to produce high-quality recyclates?
Basically, the answer is yes. The question is: how intensively would I want to do it, and what are my expectations of the end product? For example, I make a distinction between whether the packaging is produced for the food sector or for goods for everyday use.

What part of the plastic material has already been tapped and how great is the potential?
The share of established cycles, and quantities that are processed in them is absolutely small compared to the quantities of materials that enter the market and are not yet recycled. The potential for recycling is quite considerable.

What is Vecoplan’s response to changing customer requirements?
As in the other business areas at Vecoplan, the team in our business area consists of the highest-level specialists, which include plastics and application engineers, mechanical engineers, sales professionals, and project managers. It’s not solely a great deal of technical know-how that we collate within the business unit, but also extensive personal experience. In close cooperation with our customers, we offer the possibility of running test series with customer material and coordinating individual concepts in our technology center. For us as a machine and plant manufacturer, the circular economy is a great opportunity for actively shaping change.

Will a well-functioning circular economy lead to a better image for plastic?
That will certainly be the case. Plastic does not deserve its bad image. It makes an important contribution to climate protection. A study by Fraunhofer Institute UMSICHT concluded that replacing virgin granulate with recycled material in packaging will reduce climate-damaging greenhouse gases by up to 60 percent. We should learn to make use of the advantages of plastic and, on the other hand, ensure that it does not end up in the environment. The circular economy will contribute significantly towards achieving this.

 

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Safe and Clean Water With TPE Solutions

Julie Fernandes
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Safe and Clean Water With TPE Solutions

For water dispenser applications, global TPE manufacturer of thermoplastic elastomer products and custom solutions for a variety of industries, Kraiburg TPE, offers its Thermolast K DW/H series of compounds to ensure consistently safe and clean water.

Clean water is an absolute necessity for daily life and survival and there is no doubt that the availability of safe drinking water is a global concern.

Water distribution systems made of contact-safe materials are essential for providing water that is free of toxic substances, chemicals, microplastics, and other contaminants, for drinking, cooking, and general hygiene purposes.

As such, water dispensers play an important role in delivering clean and safe water to homes, offices, and other private and public places because they are portable, simple to install, and require little maintenance.

Advanced materials, such as thermoplastic elastomers (TPEs), are widely used in the manufacture of water dispenser parts and components to ensure that they always dispense clean water.

Kraiburg TPE, a global TPE manufacturer of thermoplastic elastomer products and custom solutions for a variety of industries, provides high-quality, custom-engineered TPE compounds such as the Thermolast K DW/H series that meets safety criteria and has the mechanical properties required for appliances such as water dispensers.

Superior material for water dispenser parts
Kraiburg TPE’s Thermolast K DW/H series is designed for use in products such as flexible tubes for water dispensers, as well as water outlet connectors, such as tubes and hoses, elastomer pipe fittings, couplings, flexible pipe fittings, plumbing manifolds, and other similar applications that come into direct or indirect contact with drinking water.

The DW/H series of compounds feature a low kinking tendency, thus allowing for use on accessories like shower hoses, kitchen hoses, water tap hoses in bathrooms, and related applications.

Tested and approved for safety of use
Kraiburg TPE’s plasticizer-free Thermolast K DW/H series makes it a viable alternative to PVC-P in drinking water applications.

It has also been certified in accordance to DVGW Arbeitsblatt W270, KTW, ACS (DGS/VS4 n° 200/232), WRAS: BS6920-1:2000 and/or 2014 cold water (23°C) & WRAS: BS6920-1:2000 and/or 2014 warm water (60°C).

Additionally, even without the use of biocides, it provides a surface with low sensitivity to dirt and microbial resistance.

Advantage-driven solution for manufacturers
Kraiburg TPE’s Thermolast K DW/H series of compounds can be processed by injection molding or extrusion and has good adhesion to PP, with hardness ranging from 55 to 85 Shore A, making it an appropriate solution for water drinking applications.

Furthermore, the series is available in translucent color and can be custom-colored with a compliance certificate.

Sustainability successes of our TPE
Besides the water dispenser applications, Kraiburg TPE’s recent sustainability innovations include a specially developed material solution for automotive, consumer and industry applications comprising post-consumer recycled (PCR) and post-industrial recycled (PIR) content.

 

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