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Asahi Kasei and Microwave Chemical Launch Joint Demonstration Project for Chemical Recycling of Polyamide 66 Using Microwave-based Technology

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Asahi Kasei and Microwave Chemical Launch Joint Demonstration Project for Chemical Recycling of Polyamide 66 Using Microwave-based Technology

Asahi Kasei and Microwave Chemical launched a joint demonstration project in April 2023 with the objective of commercializing a chemical recycling process for polyamide 66 using microwave technology. The process utilizes microwaves to depolymerize PA66 and directly obtain the monomers hexamethylenediamine (HMD) and adipic acid (ADA), which is expected to be accomplished at high yield with low energy consumption. The monomers obtained can then be used to manufacture new PA66. In the demonstration, scraps from manufacturing and post-use waste material of PA66 for airbags and automobile parts are depolymerized.

Asahi Kasei produces fossil fuel–derived hexamethylenediamine (HMD) and adipic acid (ADA) as intermediates to manufacture Leona PA66, an engineering plastic featuring outstanding heat resistance and rigidity. PA66 is used in various applications, including plastic parts for automotive and electronic products, and yarn for airbag fabric, and its demand is expected to increase worldwide.

As the world moves toward carbon neutrality, attention is increasingly focused on manufacturing processes for reducing greenhouse gas (GHG) emissions from chemical products derived from fossil fuels. Microwave Chemical is promoting technological and business development to achieve carbon neutrality in the industrial sector focused on process development using microwaves, which can directly and selectively heat target substances with high energy efficiency. For chemical recycling, Microwave Chemical is advancing its proprietary PlaWave technology platform for decomposing plastic using microwaves.

Through development combining Asahi Kasei’s experience in manufacturing HMD and ADA for more than half a century together with Microwave Chemical’s achievements in the industrialization of microwave technology, the two companies aim to commercialize a manufacturing process for PA66 that can reduce GHG emissions compared to the conventional manufacturing process. Laboratory-scale studies that began in fiscal 2021 have confirmed the high-yield depolymerization of PA66 using microwaves, as well as the principle of the separation and purification process after depolymerization. Bench-scale equipment will now be assembled at Microwave Chemical’s Osaka Factory by the end of fiscal 2023, and a small-scale demonstration trial using this equipment will be performed in fiscal 2024 to collect basic process data for ommercialization.

Microwave Chemical’s PlaWave technology platform for decomposing plastic using microwaves can depolymerize PA66 with low energy and obtain HMD and ADA monomers in high yield. The manufacturing process for PA66 using HMD and ADA obtained by depolymerization with this technology is expected to reduce GHG emissions compared to the conventional PA66 manufacturing process, while further reduction of GHG emissions may be achieved by the use of renewable energy for the power required to generate the microwaves.

By verifying the process from depolymerization to separation and purification in an integrated manner, this demonstration project aims to enable resource circulation of PA66 for further reduction of GHG emissions.

Moving forward, based on the results of the small-scale demonstration trial, a decision on the possibility of commercialization will be made by fiscal 2025 following detailed analysis. Concurrently with the small-scale demonstration trial, construction of a business model that involves the entire value chain in the chemical recycling of PA66 will be advanced, aiming to achieve a circular economy together with stakeholders in the PA66 value chain.

Asahi Kasei aims to be a global partner for its PA66 customers by providing optimal solutions for their carbon neutrality initiatives through studies of the practical application of material recycling and chemical recycling as well as trials for the commercialization of PA66 made using biomass-derived intermediates.

Microwave Chemical is working to increase the scale of equipment and to make PlaWave more generally applicable in order to achieve the practical application of the chemical recycling of polymethyl methacrylate (PMMA, also called acrylic resin), automotive shredder residue (ASR), plastic containers and packaging, flexible polyurethane foam, etc.

For more information, visit www.asahi-kasei.com.

 

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Arburg Showcases Itself as a Full-Service Partner

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Arburg Showcases Itself as a Full-Service Partner

  • Anniversary: Introducing the new Allrounder 470 H
  • Focus: Digitalisation and sustainability
  • More components: Allrounder More for medical technology

At Plastpol, the most important trade fair for the plastics industry in Poland and Eastern Europe, which will be held in Kielce, southwest of Warsaw, between 23 and 26 May 2023, Arburg will be represented with an appropriately innovative exhibition programme tailored to the market. On display at Stand E30 in Hall E will be the new Allrounder 470 H, which the company has launched to mark the anniversary of “100 years of the Hehl family company”. The key topics of digitalisation and sustainability will also be highlighted with a range of products and services centred around “arburgXworld” and “arburgGREENworld”. In addition, there will be a fascinating multi-component application for the medical technology sector featuring an Allrounder More.

Konrad Szymczak, Managing Director of Arburg Poland, has this to say about the Eastern European market and Arburg’s exhibition programme: “The market in Poland and Eastern Europe is still in good shape, but is currently unstable because of the situation in Ukraine. Our portfolio is primarily aimed at customers from the packaging, medical technology and automotive industries. In addition, we will be presenting turnkey solutions that showcase Arburg as a comprehensive system service provider. In Poland, we can offer the entire range of products – so not only our Allrounders and robotic systems, but also comprehensive service, fast spare parts deliveries and turnkey production systems. This is just one of the reasons why Arburg Poland has a great reputation in the market in all industry segments. With our presence at Plastpol, we want to demonstrate our capabilities and innovative strength and expand our position in the future.”

New Allrounder 470 H: 50 per cent lower energy requirement

Arburg is launching a new machine technology with the milestone machine and is now presenting the hybrid Allrounder 470 H for the first time in Polen. The machine enables customers to leverage the benefits of the combination of electric clamping unit, hydraulic injection unit and the “Comfort”, “Premium” and “Ultimate” performance variants in a way that is even more customised to their needs, coupled with a reduction in acquisition and operating costs and a significantly smaller carbon footprint. In addition to the attractive price/performance ratio, Szymczak believes that the machine’s energy efficiency and precision, comparable to that of an electric machine, is a convincing argument in its favour.

The technical facts of the new hybrid series speak for themselves: compared to a corresponding hydraulic machine, the energy footprint of the Allrounder 470 H is up to 50 per cent smaller. This means that, depending on the application, up to 12,000 kg of CO2 can be saved each year. Another feature that helps conserve resources is the new oil management concept, which not only requires around 35 per cent less oil, but also uses waste heat from the machine to preheat the oil. The required cooling water capacity is also between 50 and 70 per cent lower. A reduction in the dry cycle time of up to 33 per cent results in significantly greater production efficiency.

At Plastpol, the anniversary machine Allrounder 470 H will be producing coffee cups with a lid, which will be filled with sweets using a simple automated mechanism on the machine – making them an ideal trade fair give-away.

Digitalisation: Demo version of “arburgXworld”

Visitors to Plastpol will also be able to find out on the Arburg stand how digitalisation can be achieved in a practical way in modern injection moulding companies. A demo version of the arburgXworld customer portal with all the apps will be on hand for testing. Users can get started free of charge with apps such as  MachineCenter, ServiceCenter and Shop, which offer a better overview, simple communication, increased flexibility and faster responses. This saves considerable time and costs in day-to-day operations. At a demo screen during the fair, these basic features can be easily tried out with the help of specialists. In addition, Plastpol visitors can find out more about the arburgGREENworld programme and Arburg’s activities in the areas of sustainability, energy and production efficiency, resource conservation and carbon footprints.

Medical technology: Automated Allrounder More

Using an automated system for the production of ready-to-use two-component moulded parts, Arburg will be showing how time and costs can be saved through function integration with an Allrounder More 1600. Four Luer connectors made of PP and TPE, which are used as closure caps in the pharmaceutical industry, are produced in a cycle time of around ten seconds. The 4+4-cavity injection mould is provided by Arburg partner Braunform. The special feature: four servo-electric mould axes from Arburg’s sister company AMKmotion monitored via the Gestica control system. They control the sequences for core-back, lifting the lid, covering the closures and unscrewing the Luer threads directly in the mould. The Yaskawa six-axis robot, which is also integrated into and programmable via the Gestica control system, removes the finished parts and feeds them one by one to an inline camera inspection for quality and statistical purposes before they are deposited into containers separated by cavities.

The milestone machine will be making its debut at Plastpol 2023. The hybrid Allrounder 470 H sets the stage for a new type of machine technology that is particularly good at saving energy and conserving resources, and is efficient in production, user-friendly and reliable.

Further information about Arburg can be found at www.arburg.com

 

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No More Rolling in Plastic – Megaflex Schaumstoff Switches to Mondi’s Paper Solution for Rollpacking Mattresses

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No More Rolling in Plastic – Megaflex Schaumstoff Switches to Mondi’s Paper Solution for Rollpacking Mattresses

  • Mondi partnered with mattress producer Megaflex Schaumstoff to introduce Protector Bag ExpandForm for mattress rollpacking
  • Created from Mondi kraft paper, the new packaging is made from renewable materials and is easy to dispose of and recycle in existing paper waste streams
  • The paper bag is customisable in size, and requires little adaption to existing packing equipment

Mondi, a global leader in sustainable packaging and paper, has created Protector Bag ExpandForm, a paperbag solution with an expandable feature to safely rollpack mattresses.

Protector Bag ExpandForm replaces the current plastic packaging with a flexible and recyclable alternative. The solution is also customisable and can expand to different sizes while holding the mattress securely. The packaging is made with Mondi’s kraft paper, which is responsibly sourced and renewable, and can be recycled contributing to a circular economy. The paper bag is puncture resistant and suitable for printing, meaning brands can customise their deliveries with a high-quality finish. Unlike plastic, the paper layers are also breathable and can emit gas that can evaporate easily with this new packaging.

Megaflex Schaumstoff, a family-owned manufacturer for flexible foams and mattresses and sleeping products, is the first company to protect its products with this new packaging. Megaflex collaborated closely with Mondi and machine producer FillMatic to ensure a smooth switch from its current plastic rollpacking equipment. The collaboration meant that the new solution was quickly up and running and with only a few adaptations to the packaging machinery. Looking forward, Megaflex plans to substitute the full range of plastic rollpacking with paper by the end of 2023 using Mondi’s Protector Bag ExpandForm.

Plastic rollpack wrapping can expand up to 200% in transit, taking up space and potentially deforming outer cardboard packaging. A benefit of Protector Bag ExpandForm meanwhile is that it is dimensionally stable – saving on shipping and storage costs.

Fabio Barbieri, Sales Director Paper Bags, Mondi, says: “Consumers are actively seeking packaging that is responsibly sourced and easy to recycle. This new solution ticks both boxes: it is easier to open and to dispose compared to large rolls of plastic and avoidable packaging used previously. Protector Bag ExpandForm needs no secondary packaging to protect the product and will be stable throughout the whole delivery journey. We are proud to be the first ones to introduce this innovative solution to the market.”

Karsten Löhr, Managing Director, Megaflex Schaumstoff says: “The Protector Bag ExpandForm is a perfect fit for our mattresses and the plastic saving we estimate is significant – over 18 tonnes every year! The paper packaging is appreciated by our customers, and a big step forward in our sustainability journey, and thanks to our good partnership with Mondi we can use more sustainable packaging, that positively contributes to our sustainability commitments.”

Mondi will be showcasing the Protector Bag ExpandForm and other innovative solutions tailored to the mattress, bedding and upholstery industry at interzum in Cologne Germany, from 09 to 12 May 2023 (Hall 10.1, booth G060).

No More Rolling in Plastic – Megaflex Schaumstoff Switches to Mondi’s Paper Solution for Rollpacking Mattresses

www.mondigroup.com

 

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More sustainable basic chemicals from LANXESS

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More sustainable basic chemicals from LANXESS

  • Expanded product portfolio for polyols and oxidation products
  • Product variants with a lower carbon footprint
  • Expansion of Scopeblue sustainability label

Specialty chemicals company LANXESS has reached an important step toward more sustainability in its portfolio of polyols and oxidation products (POP): The Advanced Industrial Intermediates (AII) business unit now offers more sustainable solutions for around 80 percent of its POP portfolio. Seven of the nine products, including the chemicals trimethylolpropane (TMP), adipic acid (ADA), 1,6-hexanediol (HDO) and phthalic anhydride (PSA), have already successfully completed LANXESS’s internal Scopeblue certification. The remaining ones are to follow soon.

“As a result, we will be one of the first producers to offer our customers a choice between conventional products and products with an improved carbon footprint,” says Dr. Stephan Deutsch, Head of the Business Line POP at LANXESS. Sustainability is now much more than an end in itself for the chemical industry. “Already around 50 percent of our customers have set themselves fixed climate targets for the coming years, similar to LANXESS,” Deutsch continued. “We are therefore convinced that Scopeblue will open up important opportunities for us in the markets.”

With the Scopeblue brand label, LANXESS marks products that either exhibit a sustainable raw material content of more than 50 percent or offer a carbon footprint of less than half of that of their conventional counterparts. To demonstrate the use of sustainable raw materials along the entire value chain, LANXESS has had its production facilities in Krefeld-Uerdingen certified by TÜV Nord to the internationally recognized ISCC PLUS sustainability standard.

Sustainable and powerful

The new sustainable TMP Scopeblue contains around 54 percent n-butyraldehyde produced from biogas and offers the same properties as the conventional variant. “We have already produced the first batch of TMP Scopeblue for one of our largest customers. Currently, we are in talks with several other interested parties,” reports Dr. Maria Guixà, Global Marketing Manager TCM (Trimethylolpropane, Calcium Formate and Maleic Anhydride) at LANXESS. “As our product has a very broad application portfolio we see great potential here. Among others, TMP is used for the production of coatings, resins, UV-curable coatings as well as for polyurethane applications.”

Competitive advantage

The Scopeblue variants of adipic acid and 1,6-hexanediol, for example, are produced from bio-based or bio-circular cyclohexane. As a result, they have a significantly improved carbon footprint compared with conventionally manufactured products. “As early as 2021, we were able to offer a certified carbon footprint for our portfolio for the first time and generate added value for our customers through this transparency,” says David Berhorst, Head of Marketing AHP (adipic acid, 1,6-hexanediol, phthalic anhydride) at LANXESS. Thanks to the two nitrous oxide reduction facilities in the adipic acid plant, which decompose the nitrous oxide generated in the production process, LANXESS has already been able to manufacture these basic chemicals with significantly lower emissions than is usual in the market. “The use of bio-based raw materials now enables us to better support customer requests for more sustainable or even CO2-neutral products,” Berhorst explains.

Exploiting new opportunities

Raw materials offer the greatest leverage for further improving the carbon footprint of POP products. This is also emphasized by Eric Hendricks, Sustainability Manager at the Business Line POP. The company is therefore working on replacing more raw materials with “green” variants. “There is not yet an alternative for everything,” says Hendricks. “We are working on solutions here with partners along the entire value chain to position ourselves clearly and early on the supply side as well.”

The main demand for the sustainable POP products currently comes from Europe. But LANXESS also sees potential in the Asian and American markets – because competitors there do not yet have any green alternatives in their portfolios. “We definitely want to be an early mover in sustainability,” Deutsch summarizes. “The market will increasingly demand innovative, sustainable products in the coming years. And if we create the right basis for this with our products, which are at the very beginning of the value chain, there will be many new opportunities for our business.”

www.lanxess.com

 

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Sidel Guides Niche Cocoa Industry Ltd’s Move Into Aseptic Beverage Production to Pioneer Aseptic in PET for the First Time in Ghana

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Sidel Guides Niche Cocoa Industry Ltd’s Move Into Aseptic Beverage Production to Pioneer Aseptic in PET for the First Time in Ghana

Niche Cocoa Industry Ltd, Ghana’s largest fully integrated cocoa processor, has successfully installed its first-ever aseptic line through Sidel. The line marks a significant milestone for the company, as it makes its first venture into milk-based products in PET with the assistance of Sidel’s long-standing expertise in aseptic production.

“We selected Sidel because of its leadership in aseptic beverage production and packaging design,” said Edmund A. Poku, Niche Cocoa Industry Ltd’s Chief Executive Officer. “Our expectations were fully satisfied. Aseptic Liquid Dairy Products (LDPs) are complex to produce, and this was a new area for us. Sidel’s technical experts and dedicated local sales and project management teams partnered with us: sharing knowledge and competencies, and providing guidance every step of the way. As a result, we have successfully introduced Ghana’s first and only locally produced and aseptically bottled chocolate milk.”

Bassam Oussaifi, Sidel’s Vice President Sales, Middle East & Africa, said: “We are delighted that this project is helping our customer move a further step towards its vision of becoming Africa’s leading producer of cocoa products.”

Having chosen PET for its 100% recyclability, affordability, food integrity, and lightweight properties, Niche Cocoa Industry Ltd opted for Sidel’s Predis aseptic dry preform sterilisation technology. Offering optimum food safety and product quality, Aseptic Combi Predis has now been installed in over 200 solutions worldwide. It has made Sidel a global leader in aseptic production, a position that was confirmed by its validation by the US FDA in 2017. Known for its ease of operation, Predis also reduces water usage and chemicals consumption. Since its launch, it has successfully decontaminated more than 120 billion bottles globally.

Both parties have worked closely together to ensure the smooth delivery of a project that required Niche Cocoa Industry Ltd to utilise Sidel’s vast experience in aseptic packaging to navigate many new challenges, because of it being the first of its kind in Ghana. The line operates to a 99.6% efficiency and has resulted in a high level of customer satisfaction, noting Sidel’s leadership and quest for perfection throughout the process, in addition to providing a platform for the company to take its product to market.

Aseptic PET solution

The 16,000 bottles per hour aseptic PET complete solution integrates Tetra Pak Processing Systems technologies and the Sidel Aseptic Combi Predis with dry preform and cap sterilisation systems, two units of Gebo OptiDry, a sleeve labeller, a VersaFilm Access shrink-wrapping system, and finally a stretch wrapper. Sidel also supplied its market-leading EIT (Efficiency Improvement Tool) data acquisition and plant intelligence system, widely used to support its beverage company customers in decreasing unplanned downtime, reducing waste and costs, and increasing factory output.

Fastest-growing cocoa producer

Niche Cocoa Industry Ltd, founded in 2011, manufactures high quality, semi-finished cocoa products for export, such as cocoa liquor, cocoa butter, cocoa cake, and cocoa powder. Based in Tema, near Ghana’s capital, it is the fastest-rising local cocoa processor in the country, with an installed processing capacity of 90,000 metric tons per year. Through its consumer products arm, Niche Confectionery Ghana Ltd, the business manufactures high quality finished products for the local and export markets. These include chocolates, chocolate spreads, powdered drinking beverages and a ready-to-drink chocolate beverage. Ghana is the world’s second biggest cocoa producer and provider of the highest-quality cocoa beans in bulk.

Innovation and growth in the Africa market

Sidel has been serving the African market for many years, working closely to help its customers in beverage, food, home and personal care packaging achieve their business objectives. It contributes to the region’s economic development and sustainable responsible growth through innovations such as aseptic beverage production and other advanced packaging solutions that benefit customers and make the lowest possible environmental impact. Sidel continues to expand operations in Africa, with the opening of a new regional office in Nairobi, Kenya, to serve customers across East Africa last year.

 

www.sidel.com

 

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Borealis Bornewables Polymers for Personal Hygiene Fabrics Help Pfnonwovens Group Accelerate Its Journey Towards Climate Neutrality

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Borealis Bornewables Polymers for Personal Hygiene Fabrics Help Pfnonwovens Group Accelerate Its Journey Towards Climate Neutrality

  • PFNonwovens Group (PFN) reduces eco-footprint of nonwovens and sets new industry standard with Bornewables polypropylene (PP) for absorbent hygiene products
  • Bornewables PP from ISCC PLUS mass balanced certified second-generation renewable feedstock derived entirely from waste and residue vegetable oil streams
  • Industrial partnership embodies the Borealis EverMinds spirit of accelerating circularity and minimising carbon dioxide (CO₂) emission

The nonwovens industry is moving towards a circular business model. As the growing world population is increasingly depending on soft and lofty nonwoven materials for absorbent products in everyday personal hygiene, from baby diapers to feminine hygiene products and incontinence care, certified renewable Bornewables polymers from Borealis help manufacturers combine efficient processability with significant benefits for the climate.

Significantly better environmental profile
In order to achieve their mission and offer value-added as well as more sustainable solutions to their customers, PFNonwovens Group teamed up with Borealis to enhance their production of nonwoven materials for the personal hygiene market and set a new industry standard by using Bornewables PP resins for spunbond and meltblown solutions.

“Anticipating the growing demand for more sustainable nonwoven solutions, we have focused our development resources over the past several years on the circular sphere to accelerate our journey towards climate neutrality,” explains Tonny De Beer, Chief Product, Technology & Sustainability Officer at PFNonwovens Group. ““For PFN’s nonwoven products, fossil-based resins are today the main contributor to the carbon footprint. Therefore, using the Borealis Bornewables instead of standard fossil-based resins will significantly reduce the carbon footprint, even enabling products with a carbon footprint under zero.”

Bornewables can be used as direct drop-in replacements for comparable fossil-based polyolefins. In PFN’s nonwoven production, they required no changes to the existing manufacturing process while delivering the same high quality and performance as previous non-renewable virgin materials.

Re-inventing essentials for sustainable living
In line with Borealis’s EverMinds ambitions to accelerate action on circularity, the Bornewables PP used by PFN is made with second-generation raw material feedstock derived entirely from waste and residue vegetable oil streams. The renewable content in all Bornewables products is mass balance accredited under the ISCC (International Sustainability and Carbon Certification) PLUS certification standard, confirming their authenticity and fully transparent traceability from the raw materials to the finished products.

“The combination of our expertise in polymer science and development with PFN’s processing know-how has resulted in nonwovens that make full use of the Bornewables advantages to minimise CO₂ emissions. Together we are reducing both waste and fossil depletion, while delivering cost-efficient products for the hygiene market with a premium look and feel,” adds Peter Voortmans, Global Commercial Director Consumer Product at Borealis. “At the same time, it serves as a role model of Borealis’ commitment to re-invent essentials for sustainable living in collaboration with value chain partners who share common goals.”

Taking a stand against climate change
Borealis adopted the mass balance approach for its renewable and chemically recycled polymers to provide products addressing climate change and circularity. The mass balance approach allows manufacturers to trace the exact share of sustainable feedstock allocated to their products, and Borealis’ ISCC PLUS certificates are audited annually to ensure that all requirements are met. Mass balancing makes it possible for customers to meet ambitious sustainability targets and stay on top of changing legislation. For PFN this means that for every tonne of certified Bornewables PP used in production, a maximum equivalent amount of nonwoven material can be claimed as certified renewable.

PFNonwovens Group’s new Bornewables based products for the personal hygiene market will be on display at INDEX23, the world’s leading nonwovens exhibition, from April 18 to 21 at the Palexpo Convention Centre in Geneva at Booth 1540.

PFNonwovens production facilities.

www.borealisgroup.com | www.borealiseverminds.com

 

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Solvay and GKN Aerospace Renew their Collaboration Agreement

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Solvay and GKN Aerospace Renew their Collaboration Agreement

Partnership aims at expanding the use of thermoplastic composite materials on aerospace structures

Solvay and GKN Aerospace have signed an extension to their 2017 collaboration agreement. Under the agreement, both businesses are developing a joint thermoplastic composites (TPC) roadmap to explore new materials and manufacturing processes for aerospace structures, while jointly targeting future strategic high-rate programs. In addition Solvay will remain a GKN Aerospace preferred supplier for TPC materials.

Over the past six years, Solvay and GKN Aerospace have engaged on successful projects such as a TPC wing rib program where the use of TPC and a one shot manufacturing process enabled the development of a lighter and cost competitive part; as well as the development of a cost effective AFP TPC fuselage panel opening the door to primary structure applications.

“We are excited to continue collaborating with GKN Aerospace,” said Fabrizio Ponte, Head of Solvay Thermoplastic Platform. “Going forward our teams will specifically work on next generation TPC materials and processes for aerospace applications including commercial aviation and Advanced Air Mobility. Our particular focus on high rate manufacturing solutions for medium and large structures.”

Arnt Offringa, Director of GKN Aerospace’s Global Technology Centre in the Netherlands said: “We are delighted to renew our agreement with Solvay. Lightweight technologies will play a key role in the journey to more sustainable aviation and working together has strengthened our technology leadership in thermoplastic innovation. Collaboration will be vital as we continue to push the boundaries of technology in order to meet our sustainability targets.”

GKN Aerospace is an industry leader in the use of TPC on aircraft and Solvay’s PEKK composites and PEKK films play an important role in supporting GKN Aerospace’s TPC development activities.

Learn more at www.solvay.com

 

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Starlinger: Sustainability and Recycling for Woven Plastic Packaging at Interpack 2023

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Starlinger: Sustainability and Recycling for Woven Plastic Packaging at Interpack 2023

The Austrian machinery supplier will be showing its solutions for the sustainable use of plastic packaging at interpack 2023.

“Closed loops for plastic packaging are not only a prerequisite for counteracting environmental pollution and constantly growing mountains of rubbish, but also to conserve resources,” emphasized Angelika Huemer, Managing Partner of Starlinger & Co Ges.m.b.H. “Wherever such loops can be implemented in a sensible way, it should be done as quickly as possible. At Starlinger, we have been working on solutions to close the loop for woven plastic packaging for a number of years. Our concepts of using recycled PET or polypropylene in the manufacture of big bags and small woven bags are well received by the pioneers in the industry, and we will continue to work on them.”

Big bags become big bags again

A pioneering project in this regard will soon be underway: Using Starlinger technology, big bag manufacturer LC Packaging, PET recycler PRT – a member of ALPLA Group, and Croatian recycler Velebit will jointly implement a closed loop for big bags made of polypropylene (PP) in autumn 2023. The big bags, which PRT uses for both the transport and storage of the input materials and the rPET granules produced from them, are recycled into rPP pellets by Velebit on a Starlinger recycling plant. LC Packaging mixes the recycled pellets with virgin material and produces tape fabric which is converted to rPP big bags. The finished big bags are then supplied again to PRT.

Closed packaging cycles in the industrial sector

In order to make polypropylene big bags, the most commonly used material for this type of packaging, more sustainable, Starlinger provides a pioneering solution for the packaging industry by processing recycled PP – also from post-consumer waste – on its production lines. “Starlinger customers are already producing big bags with recycled polypropylene. If the quality of the recycled material is good, high proportions of recycled content in this type of heavy-duty packaging, which has to fulfil special requirements, are no problem,” said Huemer.

With the technology for manufacturing big bags from PET as an alternative to polypropylene, Starlinger is able to offer manufacturers in this packaging segment a solution for a completely closed packaging cycle. Properly recycled, rPET achieves properties like virgin resin and can be used up to 100% for the production of high-quality packaging – see bottle-to-bottle recycling. With Starlinger systems, it is now also possible to produce big bags from 100% recycled PET.

From plastic packaging to high-quality recyclate

Starlinger not only offers production equipment for woven plastic packaging, but also systems for the recycling and refining of plastics, which are also used in the closed-loop solutions mentioned above. Starlinger recycling technology and Starlinger viscotec play a leading role in the industry with technologies for the production of food-grade PET and HDPE recyclates as well as thermoforming films made of rPET.

With the new recoSTAR PET art PET recycling system, Starlinger recycling technology offers an energy-saving and low-maintenance machine concept that produces food-grade rPET of the highest quality and at the same time reduces production costs by around 21%. In the field of post-consumer recycling, Starlinger’s odor reduction technology helps ensure that packaging of consumer goods such as detergent and shampoo bottles can be recycled and reused in the same application, thus avoiding “downcycling”.

With the viscoZERO melt-phase decontamination reactor, Starlinger viscotec has developed a versatile system that produces recycled PS, PP, PE or HDPE suitable for food packaging applications and increases the intrinsic viscosity of PET. Unwanted odours are also effectively removed during the decontamination process. The line processes production waste from fibre and textiles production, skeleton waste, strappings, or post-consumer plastic flakes.

New sack conversion line and other highlights at the trade fair

The new Starlinger sack conversion line multiKON KX servo can be seen in operation at the booth and will produce IC*STAR sacks developed by Starlinger. In the IC*STAR production process, the cut sacks run through a welding device in which a coated sealing strip is welded onto the bottom of the sack in a continuous process using hot air in order to close it. IC*STAR sacks are characterized by material saving production, excellent protection of the product, and high strength combined with low packaging weight.

The production software provider GRAFiT will also be at the Starlinger stand during interpack. The Starlinger subsidiary offers software systems for the control and monitoring of production lines as well as product tracing which are installed also on Starlinger production lines, among others. Based on reliable information from the
production line, the software provides a clear overview of all processes, enabling an objective analysis of the production process.

The Austrian platform “Packaging with a Future” will also be present at the Starlinger booth and provide information on circularity in the packaging industry.

www.starlinger.com

 

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Aquapak Appoints New Advisory Board Member to Support Firm’s New Phase of Development

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Aquapak Appoints New Advisory Board Member to Support Firm’s New Phase of Development

Aquapak Polymers Ltd, which specialises in polymer-based material technologies which deliver both performance and environmental responsibility at scale, has today announced the appointment of Adrian Whyle to its Advisory Board, which comprises business leaders and experts in material science and the environment.

The Advisory Board provides advice and input to support Aquapak’s management team as they embark on an exciting phase of global growth and innovation. This includes bringing its innovative Hydropol technology to full-scale commercialisation, developing a portfolio around it, as well as focusing on a range of other bio-based and traditional polymers and other coatings.

Adrian brings over 30 years of highly relevant international experience gained working in the speciality chemicals industry in a number of roles ranging from pure R&D to new product development and manufacturing. Most recently, he was responsible for shaping,  promoting and implementing Plastics Europe’s strategy to increase the circularity of all plastics to achieve the plastic industry’s vision of a robust resilient plastics Circular Economy that maximises plastics reuse and recycling while minimising waste and resource use.

Commenting on Adrian’s appointment, Mark Lapping, Chief Executive Officer, Aquapak, said:

“Adrian is joining Aquapak’s Advisory Board at a very exciting time in the growth of the business as we take the commercialisation of Hydropol TM to the next level. His extensive technical expertise and understanding of Europe’s complex and often disjointed waste infrastructure is hugely valuable as we seek to promote recyclability, compostability and biodegradability as priority end of life options.”

Commenting on the role, Adrian Whyle said:

“Aquapak has developed an exciting proposition in Hydropol TM which genuinely does have the potential to transform the use of conventional plastics in packaging. I look forward to working with the management team and Advisory Board members to help accelerate the development of the product portfolio and applications.”

Adrian is joining Aquapak’s other Advisory Board members:

  • Dr Marijn Dekkers, former CEO OF Bayer AG and former Chairman of Unilever
  • Charlie Crew, former CEO of SABIC Innovative Plastics,
  • Frankie Hobro, Director and Owner of Anglesey Sea Zoo and Marine Resource Centre
  • Simon Weston, Former Director of Raw Materials, Confederation of Paper Industries (CPI)
  • Paul Jenkins, MD, ThePackHub
  • Professor Gary Critchlow, Surface & Interface Science, Loughborough University

Aquapak has successfully developed and commercialised Hydropol TM , a high-performance polymer that enables product design to provide its much-needed functionality whilst increasing recycling and reducing plastic pollution. When extrusion coated or laminated onto paper, Hydropol TM adds strength and barriers to oxygen, oil and grease, and its solubility allows 100% paper fibre recovery through paper recycling mills. As well as being biodegradable and compostable, it is non-toxic to the environment and marine-safe, so it still has a safe end-of-life if it is not disposed of as intended. It is already being used in products such as reusable, heat sealable paper mailing bags.

www.aquapakpolymers.com

 

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Ineos Styrolution Introduces Styrenics Based “Green Compounding” With Ceramic-Like Appearance

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Ineos Styrolution Introduces Styrenics Based “Green Compounding” With Ceramic-Like Appearance

  • Initial interest from producers of hygienic consumer items
  • Food contact compliant solution available as well

INEOS Styrolution, the global leader in styrenics, has today announced that a range of styrenics based polymers are an effective and sustainable alternative for ceramics, compared to traditional resin-based applications. The styrenics based approach allows for recycling and there is no loss of the distinctive appearance of ceramics. In addition, energy consumption during production is significantly lower using a styrenics based solution than firing ceramics.

Together with partner Microfol Compounding , INEOS Styrolution has been evaluating a range of polystyrene and SBC2 based solutions to act as a substitute for ceramics. The results have been very compelling, delivering excellent properties for appearance, feel and weight. In fact, the results were so convincing that producers of hygienic consumer items, such as bath tubs, sinks or soap dishes, have signaled early interest in reviewing the data and application prototypes.

The SBC material used in this project is INEOS Styrolution’s Styroflex, a copolymer with the properties of a thermoplastic elastomer (S-TPE), suitable for extrusion (including both blown and cast film) and injection molding. In particular, Styroflex contributes significantly to an increased impact strength of the new material. Today’s announcement comes only weeks after Styroflex has proven to be a superior cost-effective binder for bio based products like cork.

Combining the new compounding solution with NAS, a stiff, amorphous styrene methyl methacrylate (SMMA) copolymer also results in a food contact compliant solution.

Peter Hofmann, Managing Director, Microfol Compounding, says: “At Microfol, we love finding innovative solutions to challenges in plastics. We are excited to be part of a development that may change how we work with ceramics, a material that is around for almost 30,000 years.”

Stefan Meier, Business Development Manager at INEOS Styrolution, comments: “The versatility of styrenics continues to amaze us. The material – we also refer to “Ceramic White” – is a viable alternative for many uses and its recyclability always comes as a very much appreciated bonus on top.”

More information: www.ineos-styrolution.com

 

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