New Milestone In Recycling: In A Pe Film Using Ecolam Laminates’ Waste.

Optimizing the recyclability of packaging is one of the most important steps into a more sustainable future. With its EcoLam product line, packaging manufacturer Constantia Flexibles shows that packaging can offer a high barrier and a high recyclability at the same time – an important step towards a circular economy that ensures valuable resources are saved.

Making packaging materials that are both more sustainable and offer good barrier properties is a challenging yet important task for packaging manufacturers. Constantia Flexibles, an Austrian manufacturer of flexible packaging, is devoting a significant number of resources to this task.

As early as 2019, its EcoLamHighPlus material became the first and only high-barrier laminate to be tested by the RecyClass Initiative of European Plastics Recyclers for its recyclability in the existing LDPE (low density polyethylene) recycling stream. It was successfully proven that polyethylene laminates with high barrier properties, which were previously only achievable with aluminum laminates, can also be recycled.

The packaging company has reached another milestone: an industrial recycling trial of EcoLam laminates. The production waste from different EcoLam family laminates, including EVOH (ethylene-vinyl alcohol copolymer), metallization, adhesives and inks, was shredded and sent for reprocessing. Our partner EREMA successfully reprocessed it into regranulates on an industrial scale extruder. These regranulates were then converted into a new blown film in Constantia Pirk, which was then used in the lamination of new EcoLam materials as a sealant.

Depending on the ink system used, recycled content of up to 80% in the lamination film was achieved – only the sealing layer has to be made from so-called “virgin material” due to its functionality. Constantia Flexibles has demonstrated that printed and metallized PE-based laminates from the EcoLam family can be reprocessed into new films with up to 80% of recycled content, closing the loop for its use in non-food packaging applications.

Further examinations showed that the type of adhesive, as well as the type of printing inks used, has a significant influence on the quality of recyclable material. It is under further investigation whether printed laminates can also be reused in food applications with suitable adhesives and inks. Regranulates from production waste consisting of vacuum metallized films, without adhesives and printing, can even be used in the food contact.

“In a circular economy, it is crucial that recyclable packaging laminates can be reused by the laminate manufacturers themselves, as is already the case for many coextruded films, i.e., films consisting of several materials,” comments Prof. Dr. Achim Grefenstein, Senior Vice President of Constantia Flexibles’ Research & Development Group. According to Grefenstein, “The current practice of incinerating or downcycling production waste will then be a thing of the past – an important step towards a more sustainable future.”

For more details: www.cflex.com

Constantia Flexibles Is Fully Committed To A Circular Economy With Its Recyclable Range Ecolutions

The packaging industry is changing as more and more consumers are questioning packaging. Latest Global Buying Green Report revealed: Two-thirds (67%) of consumers consider it crucial to buy products in recyclable packaging. Constantia Flexibles recognized the trend years ago and has continuously developed its products. The company will present its highlights and updates at FachPack 2021 in Nuremberg, Germany.

“Our strong focus is to continue to develop more sustainable film, aluminum, and paper-based packaging for our clients,” Pim Vervaat, CEO of Constantia Flexibles, explains the company’s goal. Constantia Flexibles’ “Ecolutions” product range meets the sustainability requirements with a clear focus on recyclability whilst continuing to have all the properties required to protect the packaged products. The latest product developments will be on display at FachPack.

Constantia Flexibles will also present its aluminum-based product range at FachPack since aluminum is a versatile packaging option. The company records more than half of its business – Pharma and Consumer combined – with aluminum-based solutions. “In Europe, aluminum packaging recycling achieves a recycling rate of 65%, rising steadily thanks to ever-improving collection and recycling techniques,” continues Vervaat. “Any material we use focuses on recyclability. Our product portfolio is broad, and we are ready for the future!”

EcoLam laminates are configured using several PE-based building blocks developed by Constantia Flexibles: OPE, barrier OPE, and met OPE, which in combination with the appropriate sealant PE, can give rise to structures able to substitute non-recyclable laminates such as PET/PE, PA/PE, or even PET/ALU/PE.

Several characteristics make the Mono PE laminates EcoLam more sustainable and efficient than other products in its league: they are thinner than others, have higher thermal resistance, and use lower barrier polymer content, due to the combination of processes and resins. All EcoLam grades have been certified by RecyClass to be compatible with readily available sorting and recycling technologies commonly used at an industrial scale in the recycling sector in Europe.

Another advantage of the EcoLam packaging line is that its barrier properties can be adapted to the product to be packed: from EcoLam, which presents a moisture barrier, to EcoLamPlus, that incorporates an additional barrier to oxygen, aroma, and mineral oil, up to EcoLamHighPlus, which shows aluminum-like barrier properties.

Further, dry pet food, confectionery, cereals and pasta, and laundry products can be packed in EcoLam. Because of the enhanced oxygen barrier, EcoLamPlus is, amongst others, suitable for dressings, cheese, and dairy products. EcoLamHighPlus provides an exceptional barrier against both moisture and oxygen, being the ideal packaging for coffee, snacks, dehydrated products, compote and baby food, perfumes, and other personal care products.

Optimizing the recyclability of packaging is one of the most critical agenda items for the future. In 2019, Constantia Flexibles’ EcoLamHighPlus material was the first and so far only high-barrier laminate to be tested by the RecyClass Initiative of European Plastics Recyclers for its recyclability in the existing LDPE (low density polyethylene) recycling stream, receiving technology approval. The packaging company has reached another milestone: after establishing a European supply chain, sufficient quantities of production waste from EcoLam family laminates were available for an industrial recycling trial. The production waste was shredded and reprocessed into regranulates on an industrial scale line in cooperation with EREMA. These regranulates were then converted into a new blown film in Constantia Pirk, which was then used in the lamination of new EcoLam laminates – thus closing the loop for its use in non-food packaging applications. Constantia Flexibles achieved a recycled content of up to 80% in the lamination film, proving that printed and metallized laminate waste can be reprocessed into new EcoLam laminates.

EcoPaper family compiles a wide range of recyclable paper-based packaging solutions. EcoPaperPlus is one dedicated to medium barrier applications. It is especially suitable for products that require aroma and grease barrier, such as confectionery, and some snacks, home and personal care. The material is available with a smooth or a rough surface shine and is printable by rotogravure, flexo, or digital. Paper FSC or PEFC certified is available on demand.

Premiere for a whole family: It is the first time these products are shown at a tradeshow. EcoVer is Constantia Flexibles’ mono-PP solution, available in different barrier grades: EcoVer, EcoVerPlus, or EcoVerHighPlus. Its key benefit is that it is applicable in various packaging applications (VFFS, HFFS) and has high transparency. It is particularly suitable for applications such as beverages, snacks, confectionery, HPC, pet care, or processed food. EcoVer’s thermal resistance is exceptional: It has an enhanced outer layer in combination with a low SIT sealant layer for a wider sealing window. The packaging has good heat resistance and provides good stiffness. Due to its mono-PP structure, the EcoVer Family is recyclable in the mixed PO stream.

More sustainable coffee consumption is possible with the new lidding of Constantia Flexibles. With its compostable and biobased material, EcoPressoLid is designed for closing the upper or the lower side of compostable coffee capsules. Compostability test was performed according to EN 13432 with satisfactory results. Among its main properties, EcoPressoLid has a high oxygen barrier and has demonstrated good performance in the brewing process due to its high seal strength and suitable perforation.

EcoAluTainer is an aluminum-based foil container system used for pet food, coffee, and various foods such as tuna or jam. All materials are free of critical substances such as BPA and GLYMO. In addition, no chrome-treated foil is used for this packaging solution. It is easily recyclable in the aluminum stream and can even contain recycled content. Further, ASI-certified aluminum is available on demand.

ComforLid is a perfect addition to Constantia’s Ecolutions family product range. It guarantees a comfortable drinking pleasure without the use of plastic over clip or straws. Additionally, ComforLid contributes to the reduction of plastic waste by substituting the plastic snap-on topper and providing a hygienic drinking experience due to the 2-layer protected opening. ComforLid is suitable to apply to PP-based cups and can be used for liquids like coffee drinks, drinking yogurts, whey, or soft drinks. Due to its customizable laser-cut opening, ComforLid offers an easy dosage for solid products as well, such as muesli, chewing gum, or dried herbs. Furthermore, ComforLid can be fully peeled off by the consumer and is therefore certified as compatible for Recycling by CyclosHTP (up to 99%).

For more details: www.cflex.com

Aiding the switch to safer e-mobility

It seems the electric revolution is finally here. According to the International Energy Agency, there were more than ten million electric cars on the world’s roads already at the end of 2020 – up 43% from 2019. By the end of this decade, the total number of electric cars, buses, vans, and trucks is projected to jump to 145 million or possibly even 230 million if enough countries tighten their emission targets. Carmakers are investing billions to secure their slice of the market. One of the challenges they face in building mass-market electric vehicles (Evs) is fire safety. But probably not in the way most people think.

Contrary to what action movies would have you believe, cars rarely burst into flames. If they ever do catch fire, passengers usually have more than enough time to walk away safely. That is why fire safety regulations for cars are a lot less strict than for planes, trains, or even most electronics used in homes. But now, with the advent of Evs, news reports of burning Evs have caused new concerns.

According to the US National Fire Protection Association (Nfpa), electrical failures are already one of the leading causes for fires in conventional cars, accounting for one in four vehicle fires in the United States. With Evs carrying high energy in their lithium batteries, it seems only logical that they pose an even greater fire risk. Not so, says Sebastian Hoerold, Head of Technical Service Thermoplastics & Market Manager Flame Retardants at Clariant: The fire risk of electric vehicles is not higher but different from traditional cars with combustions engines.

Electric power trains work at much higher voltages and currents. Most conventional cars carry a twelve-volt battery to run the starter, lights, and all onboard electronics. Even so-called mild hybrids, in which a powerful electric motor supports the combustion engine, run on just 48 volts. In contrast, some all-electric vehicles have fast-charging cycles that can involve 800 volts or more.

Then there are the differences in everyday use: Parking a diesel essentially puts the car to sleep. But parking an Ev usually involves charging it. We see some of the highest voltages and currents precisely as the car is unattended, says Hoerold. That can be overnight in your garage or during the day in a public parking area, say, underneath a busy shopping center or an office building. It is this combination of high-energy batteries, high voltages and currents during charging while being unattended that needs to be considered in safety standards.

Up until recently, the automotive industry was not much of a market for our high-performing flame retardants. However, that is about to change dramatically, says Elmar Schmitt, Segment Manager for Clariant’s flame retardant business. In reinventing their product, carmakers will need new materials with safety built in to deal with a whole new set of challenges and requirements.

First, there are the high voltages. These can cause short-circuits and sparks that can ignite flammable materials. One of the ways to prevent such failures is by design: Simply placing conducting parts further apart is one strategy. Another is to encase components. But these approaches aren’t always practical in car design. For one, cars are crammed with ever more electric hardware. Spaces are tight. Components need to fit close together. Adding material and assembly work to encase components drives up costs and adds weight. Carmakers have always been sensitive on these two fronts, says Schmitt. Even small extra costs add up quickly, so does excess weight. Every gram you can shave off an EV adds to its battery range, which is currently one of the most important selling points.

High-voltage plugs, connectors, bus bars and other electrical components require high-performing polymers with high-performance flame retardants – such as Clariant’s Exolit. It has been in use for two decades in some of the most demanding industries, from smart consumer electronics to home appliances to industrial applications. Based on organic phosphorus compounds, Clariant’s additives can stop plastics burning within seconds and thus stop flames from spreading. It also helps minimize the risk of creepage and sparks. Exolit is non-halogenated, which makes it safer and more environmentally compatible than most solutions out there, says Schmitt.But it is the improved material performance that makes it especially appealing to the EV industry.

Adding Exolit to plastics does not affect or in some cases even improves their electrical properties – measured as the Comparative Tracking Index (Cti). We enable manufacturers to reach Performance Level Category 0, which holds for 600 volts, Hoerold explains. That way, conducting parts can be fit closer together, allowing further miniaturization and weight cutting. Plus, Exolit itself adds remarkably little weight to the parts.

Then there is the matter of durability. Standard cars are expected to last up to 200,000 miles. With fewer moving parts, EVs may get even more mileage. However, that heavily depends on how well connectors, plugs, cables, brackets, and the likes hold up to the constant stress caused by vibration, extreme temperatures, UV light, corrosive liquids, dust and moisture. High voltages and humidity can further exacerbate this stress through a process called hydrolysis. Over time, it can break down materials within the polymer and lead to corrosion in the pins and connectors, Hoerold explains. Exolit is hydrolysis-stable and can be used in dedicated hydrolysis resistant formulations as well.

Probably the most important draw to carmakers is how little the addition of Clariant’s flame retardants affects a polymer’s other properties. The automotive industry has made an art of engineering cars to optimize costs, production speed, durability, and so on, Schmitt says. They want their polymers to perform the way they’re used to. However, most flame retardants make plastics more brittle, less workable, and even less durable overall. Some make specific production processes harder or even impossible. With Exolit, we have carmakers covered, says Hoerold. For example, they are very satisfied with the way it works with both laser welding and laser marking. Plus, it affects the physical properties of the plastics as little as possible.

For more details: www.clariant.com