recycling: economic and eco-logic acceleration€¦ · recycling: economic and eco-logic...

Recycling: Economic and Eco-Logic Acceleration

Peter Heydasch, CAE

Dow Europe GmbH

Stakeholder Conference

September 29th, 2015

Brussels, Belgium

®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Dow in a Nutshell

58.2 billion US$ in sales

180 countries where we serve customers

53,000 employees

+6,000 products

Source: Dow 2014 Annual Report


Embedded in everything we do

Operations, strategy, innovation agenda and daily actions

1. Leading the Blueprint

2. Delivering Breakthrough Innovations

3. Advancing a Circular Economy

4. Valuing Nature

5. Increasing Confidence in Chemical Technology

6. Engaging Employees for Impact

7. World-leading Operations Performance

• U.S. Presidential Green Chemistry Challenge Award

• Dow Jones Sustainability World Index

• A+ rating from the Global Reporting Initiative (GRI)

• UN Global Compact www.dow.com/sustainability

Recognitions

2025 Goals Sustainability

Page 3

Goal #3: Advancing a Circular Economy

By 2025, Dow will work with other industry leaders, non-profit

organizations and governments to deliver six major projects

that facilitate the world’s transition to a circular economy, where

waste is designed into new products and services.

http://www.dow.com/sustainability


The Polyethylene Chain

• Shrink & Stretch Wrap

• Food Packaging Film

• HIC Bottles

• Agricultural Film

• Retail bags & Sacks

• Trash &Can Liners

• Heavy Duty Sacks

• Paperboard Coating

• Gas & Water Pipes

• Wire & Cable

• Caps & Closure

• Beverage Bottles

• Housewares

• Industrial & Multiwall Sack

Liners

• Rotomolding

• Crates & Boxes

• Protective Film

• Diaper & Sanitary Film

• Industrial & Sewer Pipes

• Personal Care Bottles

• Automotive

• Profiles

Products Polymerization

Solution ULDPE, LLDPE

HDPE

Gas-Phase LLDPE

HDPE

High-Pressure LDPE

EAA, EVA, ...

Slurry HDPE

400–650 KTA per plant 85 million tons globally

Blown Film • Standard 6-7 KTA • Barrier film ~3 KTA

Blow Molding

Cast Film, Sheet & Thermoforming • Standard 7-8 KTA • Barrier film ~4 KTA

Pipe Extrusion • Standard 5 KTA

Other

Injection Molding • Standard 3 KTA

Rotomolding

Conversion Machinery & Processes


0

500

1,000

1,500

2,000

2,500

1991 1995 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

PrivateEnduser [kt]

Industry &OtherEnduser [kt]

Dynamic of Plastic Packaging

Structural Effect

Shape & Size

+ 309 kt

Weight Effect

Thickness

Reduction

- 955 kt

Quantity Effect

Growth &

Substitution

+ 1’759 kt

Exemplarily displayed by development

in Germany 1991-2013

Source: BKV-Studie „Entwicklung der Effizienz von

Kunststoffverpackungen 1991-2013

1991

1’642 kt

2013

2’760 kt

changes in

consumer behavior downgauging efforts

by the industry increased

functionality


Resource Efficiency

Resource

Efficiency

Resource

Efficiency

DfS Design-for-

Sustainability

+ =

Source of Material Reduction: BKV-Studie „Entwicklung der Effizienz von

Kunststoffverpackungen 1991-2013

• Cups -14%

• Containers -32%

• Bottles -33%

• Flexible Packaging -36%

• Closures -42%

Red

uce

d W

eig

ht

• Freshness

• Hygiene

• Safety

• Shelf Life

• Visibility of Content

• Provides Information

• Shelf Appeal

• Production Energy

• Transport Energy

• Right Portion

• Dosage

• Easy Storage

Fu

nct

ion

alit

y

FLEXIBLE PACKAGING

low product-to-pack ratios,

reduced transport costs and emissions


Eco-Logic Evaluation

Plastics contribute significantly to increased resource efficiency

even when recycled at a lower rate than other materials

•1-5 layer Shrink & Stretch Film

(LDPE/LLDPE + Elastomer)

•1-7 layer Agricultural Film

(LDPE/LLDPE) •1-3 layer Trash & Cans Liners

(LDPE/LLDPE + rPE)

•3-5 layer Heavy Duty Shipping

Sacks (LDPE/LLDPE)

•1 layer Retail Bags & Sacks

(LDPE/LLDPE + rPE)

•1 layer Caps & Closures

(HDPE) with Elastomer +

Barrier inserts

•1-5 layer Beverage Bottles

(LLDPE/HDPE + Tie + EVOH)

•1-3 layer Beverage Bottles

(HDPE + rPE)

•6 layer Paperboard Coating

(LDPE/LLDPE + EAA +Aluminum) •3-7 layer HIC Bottles

(HDPE + EVOH + rPE)

•3-11 layer Aluminum Laminates

(LDPE/LLDPE/HDPE + Adhesive +

Aluminum + PP/PA/PET)

Resource

Efficiency

in Packaging

•3-11 layer Food Packaging Film

(LDPE/LLDPE/HDPE + Tie +

EVOH + PP/PA/PET)

Innovation

Exemplary packaging types, no automotive, electronics or other segment included, although generally valid

Today, there is a clear break-even point where mechanical recycling is counterproductive

in terms of environmental benefits and costs


New Sensor Based Sorting System

• Low energy consumption, less light sources

• No active cooling, dust proof scanner

• No lamp arms, easy maintenance

• More homogenous and dirt protected

illumination

FOOD NON-FOOD

Milk, chocolate, juice, … Bath cleaner, laundry detergents, .…

Higher definition of spectra allow finer sorting

• HDPE food container versus detergent containers

• PET bottles versus PET trays or polyester textiles

First installations realized by TOMRA

By courtesy of TOMRA Sorting Solutions

Titech Autosort 4


Recovery of Agriculture Films

http://www.erde-recycling.de/en/sustainability/recycling.html

RIGK GmbH provides the safe

and sustainable return and

recovery of any plastic

packaging, hazardous and non-

hazardous, to industrial and

agricultural companies.

http://www.rigk.de/en/profile.html

By courtesy of RIGK GmbH

ERDE concept for crop plastics


Step Changing Technology Developments

Step changing technology development in the last 5 years

ecoSAVE® Energy-efficency

•Saves up to 14 %

energy and

subsequent CO2

emissions

•Handles heavily printed

film, mixed plastics,

washed film flakes and

multilayer film

COREMA® Recycling &

compounding in

a single step

VACUREMA® Global leader in PET- &

HDPE bottle recycling

2015+ TVEplus® Superb degassing,

homogenization &

filtration

•Significant expansion

of markets for

recycled plastics

•Effective decontamination

•Food Contact Control

•IV Control (securing high

molecular weight)

The next step Removal of smell

•EREMA has developed a

solution which is ready for

discussion on a case-to-

case basis

By courtesy of EREMA Plastic Recycling Systems


EVOLUTION Ultra Fusion Technology

Twin Screw Compounding Extruder

•Gravimetric pellet dosage

•Gravimetric powder dosage

•Optional liquid dosage

•Vacuum devolatilization

•Melt filtration

•Melt pump

Single Screw Extruder

Single Screw Extruder

FFS for turf or flower soil Heavy Duty Shipping Sacks (HDSS)

Mulch Film Refuse Bags

•Direct extrusion of CaCO3 powder

•In-line-recycling with compatibilizer

By courtesy of Reifenhäuser Blown Film


RETAIN™ Polymer Modifiers:

• Based on a reactive ultra-low viscosity

• Allow pelletized barrier films, containing materials like ethylene vinyl

alcohol (EVOH) or polyamide (PA), to be more evenly dispersed

into a polyolefin matrix

• Helps make clearer packages, maintain mechanical properties

and significantly reduce gels in films produced from barrier film

recycle streams

Compatibilizers from Dow

Transmission Electron Microscopy

Optical Microscopy

No compatibilizer

Large EVOH domains

Conventional compatibilizer

Bimodal EVOH domains RETAIN™ 3000

Small, uniform EVOH domains

No compatibilizer

Large EVOH domains

Conventional compatibilizer

Bimodal EVOH domains RETAIN™ 3000

Small, uniform EVOH domains

Other resin compatibilizers from Dow:


Microwave Induced Pyrolysis

+

By courtesy of ENVAL Ltd.

Plastic laminates with ~10% Aluminum Aluminum Condensed Hydrocarbons

“Recycling the Unrecyclable”


Accelerating the Loop …

Resin

Producers

Resin

Converters

Implement increased

functionality and

reduced weight

Brand

Owners/Fillers

Energy

Recovery Landfill

Consumers

Retailers

Collection/

Sorting

Economic

Acceleration

by Pull

Strategies

Regranulators/

Compounders

Recover properties

and expand applications


Ap

plicati

on

Dev

elo

pm

en

t

Material

Science

Process

Research

Catalyst

Research

Research

Supply Chain

Converter OEM’s

Brand

Owner

Retailer

Market

Management

Teams

Development

Commercialization

Man

ufa

ctu

ring

… With Partners in the Value Chain


• Expand landfill ban in Europe

• Sorting quality is key

• Competition on equal and fair terms

• Innovation to improve cost-benefit balance of recycling

• Environment for further innovation and investments

• Mechanical recycling not an end in itself

• Design-for-Sustainability (DfS) to achieve highest resource efficiency

• Pull strategies from brand owners and retailers

• Value Chain collaboration. Meet us at our Pack Studios!

Thank You


Quotes

Source: PlasticsEurope: Plastics – the Facts 2014/2015


Source: PlasticsEurope: Plastics – the Facts 2014/2015

Quotes


Source: DENKSATT 2014, How Packaging Contributes to Food Waste Prevention

Quotes


Source: PlasticsEurope: Eco-Efficient Plastic Waste Management Webinar 25 September 2015

Quotes


Source: DKR mbH, Stakeholder Conference, Brussels, September 29th, 2015

Quotes

recycling: economic and eco-logic acceleration€¦ · recycling: economic and eco-logic...

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