recycling: economic and eco-logic acceleration€¦ · recycling: economic and eco-logic...
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Recycling: Economic and Eco-Logic Acceleration
Peter Heydasch, CAE
Dow Europe GmbH
Stakeholder Conference
September 29th, 2015
Brussels, Belgium
Page 2 ®™ 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
Page 3 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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.
Page 4 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
Page 5 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
Page 6 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
Page 7 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
Page 8 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
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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
Page 10 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
Page 11 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
Page 12 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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:
Page 13 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Microwave Induced Pyrolysis
+
By courtesy of ENVAL Ltd.
Plastic laminates with ~10% Aluminum Aluminum Condensed Hydrocarbons
“Recycling the Unrecyclable”
Page 14 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
Page 15 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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
Page 16 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
• 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!
Page 18 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Quotes
Source: PlasticsEurope: Plastics – the Facts 2014/2015
Page 19 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Source: PlasticsEurope: Plastics – the Facts 2014/2015
Quotes
Page 20 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Source: DENKSATT 2014, How Packaging Contributes to Food Waste Prevention
Quotes
Page 21 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Source: PlasticsEurope: Eco-Efficient Plastic Waste Management Webinar 25 September 2015
Quotes
Page 22 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Source: PlasticsEurope: Eco-Efficient Plastic Waste Management Webinar 25 September 2015
Quotes
Page 23 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Source: PlasticsEurope: Eco-Efficient Plastic Waste Management Webinar 25 September 2015
Quotes
Page 24 ®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Source: DKR mbH, Stakeholder Conference, Brussels, September 29th, 2015
Quotes