From the Sector

After its launch on 20 September 2020, the RCI is proud to celebrate its first anniversary this fall. The balance sheet of the first year is impressive: starting from 11 founding members, that number increased to 30 member companies within 12 months. Numerous webinars, press releases, background information, a glossary and a comic allowed to convey the “Renewable Carbon” concept to the public. The RCI is actively working on labelling and policy analysis, and more activities will follow in the next year.

Key for this success: the topic of renewable carbon in chemicals and materials is increasingly becoming a focus of politics and industry. Larger companies will have to report their GHG emissions and also the footprint of their products as part of legislative changes surrounding the European Green Deal. In this context, indirect emissions and the carbon sources of materials will play a much more crucial role. The RCI is actively working on solutions for companies to shift from fossil to renewable carbon, which consists of the use of bio-based feedstock, CO2-based resources and recycling. In the future, reporting on GHG emissions will also include Scope 3 emissions, which are all indirect emissions that occur along the company’s value and supply chain and where the used raw materials account for a large proportion of the footprint. Here is where the carbon source of chemicals and plastics comes into play as an important contributor to the carbon footprint. Without a shift from fossil to renewable carbon feedstocks (combining bio-based, CO2-based and recycled), a sustainable future and the Paris climate targets will be almost impossible to master.

To discuss, promote and realise the shift, 30 innovative companies have already joined forces to support the transition to renewable carbon, considering both technological and economical approaches – and helping to shape the political framework accordingly.

For the second year, RCI plans to focus on a comprehensive understanding of the expected political framework conditions in Europe and across the globe, since they will determine the future of chemistry and materials more than ever. Building on this knowledge, the topic of renewable carbon could then to be systematically integrated into new political directives, which has so far not been effectively managed.

In reality, the political focus lies on the strategy of decarbonising the energy sector, a very central and Herculean task. However, it cannot be applied to the chemical and material world because carbon is usually the central building block that cannot be dispensed with. On the contrary, the demand for carbon in the chemical and materials sectors is expected to more than double by 2050. In order to meet this demand in a sustainable manner, we must move towards quitting fossil carbon. For the first time in industrial history, it is possible to decouple chemistry and materials from petrochemicals and completely cover the demand through the utilisation of biomass, CO2 and recycling.

Recycling is the key factor in achieving the EU climate targets. This is shown by the results of the "resources SAVED by recycling" study published today, which Fraunhofer UMSICHT prepared on behalf of the ALBA Group, one of the ten leading recycling companies worldwide. According to the study, 3.5 million tons of greenhouse gas emissions and 28.8 million tons of primary resources could be saved in 2020 alone. Further potential could be raised, for example, through minimum quotas for the use of recycled raw materials.

“Fit for 55” thanks to the circular economy: the recycling of raw materials leads to a systematic reduction in the greenhouse gas emissions of our civilisation – and can therefore make a key contribution to achieving the EU climate goals. This is the outcome of the “resources SAVED by recycling” study presented today, which the Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT prepared on behalf of the ALBA Group. Thanks to the closed-loop circulation of 4.8 million tonnes of recyclable materials, the ALBA Group succeeded in preventing some 3.5 million tonnes of climate-damaging greenhouse gas emissions in the year 2020 alone. This amount is equivalent to the emissions from some five million return flights between Frankfurt am Main and Mallorca. At the same time, recycling also secures valuable raw materials for the industry: in 2020, in comparison with primary production, recycling saved 28.8 million tonnes of resources, such as crude oil and iron ore.

“The circular economy is one of the strongest pace-setters on the journey to achieving climate neutrality,” highlights Dr. Axel Schweitzer, CEO of the ALBA Group. “We will only achieve the goal of reducing greenhouse gas emissions by at least 55 per cent throughout Europe by 2030 if we make consistent use of recycled raw materials.” This includes the area of plastics, for example: compared with primary plastics made from crude oil, the use of high-quality recycled plastics achieves a reduction of greenhouse gas emissions of more than 50 per cent. “It is now necessary to lever this potential,” explains Schweitzer. “We are expecting the new Federal Government in Germany to act decisively and push ahead directly with the transition to a circular economy. The environmental benefits of recycling due to its clearly superior CO2 balance should also find reflection in prices. As immediate climate protection measures, clear industry standards for recyclates combined with minimum quotas on the use of recycled raw materials in products and packaging are also urgently necessary. Last but not least, the state sector is also called upon to prioritise resource protection in the area of procurement. Sustainable procurement can ultimately provide a significant boost to the circular economy”.

Plastics, metals, waste electrical (and electronic) equipment, wood, paper, cardboard, cartons or glass: the Fraunhofer UMSICHT has now been researching the specific benefits of recycling for 14 years. Detailed comparisons have also been made of the primary processes and recycling processes for the various material flows. “This means we can precisely quantify the extent to which the recycling activities of the ALBA Group can contribute to reducing the burden on the environment,” explains Dr.-Ing. Markus Hiebel, Director of the Department for Sustainability and Participation at Fraunhofer UMSICHT. Hiebel believes that the greatest savings can be achieved if the entire value chain is aligned consistently with the circular principle: “The transformation towards a genuine circular economy requires completely new thinking. Products should be designed and managed to ensure that they contain recycled raw materials right from the start – which enables them to be recycled appropriately.”

Not only since 2021 has sustainability been a topic high on society’s agenda. And yet the importance of sustainability for consumers and companies has once again increased sharply as a result of the Corona pandemic, as numerous studies confirm. Then why is it often so difficult to implement this conviction in everyday life? One of the biggest obstacles to sustainable consumer behaviour is the lack of availability of alternatives.

In addition to changing consumer demands, the EU Commission's recent decision on the single-use plastics directive is also prompting many nonwovens manufacturers to look at alternative solutions. Kelheim Fibres is exhibiting at this year's INDEX in Geneva and online with bio-based fibers that offer an alternative to synthetic materials in a wide range of applications. The Bavarians have decades of experience in the nonwovens and hygiene sectors and work on individual customer-specific innovations.

"We want to make it easy for consumers to choose an environmentally friendly option. That’s the case when bio-based solutions offer the same performance as synthetic products," said Matthew North, Commercial Director at Kelheim Fibres." Our fibre technology allows us to create just that: unlike natural fibres, which are available already in fibre form and can only be treated on the surface, we can engineer the properties of our fibres they need for specific applications by specifically intervening in the production process. That way we combine nature - our fibres are made of wood pulp - with performance."

Kelheim's special fibres are made of wood pulp from sustainably managed sources, are produced in Kelheim in an environmentally friendly way and are fully biodegradable at the end of their product life. Kelheim Fibres is the first viscose fibre manufacturer in the world with an EMAS validated Environmental Management System and was awarded a dark green/light green shirt in the most recent Canopy HotButton-Ranking.

A sector alliance that was formed to tackle issues relating to microplastics has completed the next phase of its project to develop a harmonised industry standard for the supply chain. The Cross Industry Agreement (CIA) has revealed the results of a fibre fragmentation trial that has been carried out in advance of establishing a CEN Standard (from the European Committee for Standardization). Once confirmed, the standard will also become an ISO standard under the Vienna Agreement, providing apparel manufacturers and policy makers with a vital tool as part of wider work to reduce microfibre shedding into the environment.

In 2018, five industry organisations agreed to join forces to proactively tackle the issue of microplastics, and signed the Cross Industry Agreement. The initial signatories were European industry associations that represent the European and global value chains of garments and their associated maintenance – the International Association for Soaps, Detergents and Maintenance Products (A.I.S.E.), European Man-Made Fibres Association (CIRFS), European Outdoor Group (EOG), EURATEX the European apparel and textile industry confederation, and the Federation of the European Sporting goods Industry (FESI). Together, the five organisations understood that the very first step to enable global action around the topic, was to agree a harmonised test method which would allow the collection and comparison of globally generated data, to aid the identification of solutions.

The microfibre shedding test method was developed thanks to the joint efforts and cooperation of experts from 28 European, American and Asian organisations; the result was handed over to CEN in 2020. Since then, representatives from the CIA have been working with CEN to fine tune details in order to meet the requirements for a CEN Standard. To verify the reproducibility of the method, the partners have carried out a round robin trial (RRT) to determine if the method could be replicated in different laboratories and produce similar results. 10 organisations participated in the RRT, which was co-ordinated by the CIA, sending fabric samples to all of the laboratories involved and then collecting and analysing the data.

The results from the RRT show statistically significant consistency, both within and between participating laboratories, which demonstrates that the method is both repeatable in the same setting and reproducible in other laboratories.

The CIA has submitted the results of the RRT to CEN, with the intention that the CEN Standard is confirmed in the near future. Once that has happened, it will be promoted throughout the apparel industry and will become a key tool for researchers, businesses and governments as they accelerate efforts to reduce microfibre shedding associated with garment production.

• From fossil to renewable materials: Members advocate policy analysis and focused implementation of the renewable carbon strategy

The members of the Renewable Carbon Initiative (RCI) (www.renewable-carbon-initiative.com), founded in September 2020, have joined forces to shape the transition from the fossil to the renewable age for the chemical and materials industry. This means spreading the concept of renewable carbon and developing new value chains based on renewable carbon as a feedstock.

In the meantime, several activities have started from which future members can benefit as well. First and foremost is the kick-off to comprehensive policy analysis. What influence will forthcoming regulation have on chemicals, plastics, and other materials? When and where should the renewable carbon idea be emphasized and referred to?

The policy analysis will examine pending policies in the European Union – and a later expansion to America and Asia is planned as well.

A particular focus will be placed on upcoming policies and regulations and how they impact renewable carbon. The members are currently deciding on where to start specifically, but questions that may be considered are: What does the new climate law and the “Fit for 55-Package” mean for chemicals and materials? What can be expected from REACH and microplastics restrictions? How relevant is the “Sustainable Products Initiative” and the coming restrictions for Green Claims? Circular Economy, Zero Pollution and Sustainable Financing are keywords of the future European landscapes, which might become very concrete for chemistry and materials in the next few years. To what extent the concept of renewable carbon for materials is considered in policy already and how it could be further introduced in future legislation are two of the main questions investigated in the working group “Policy”.

This working group is open to all members of RCI. Policy experts provide the respective analysis as a foundation, organising discussions between members of the policy group and plan meetings with policymakers to introduce the Renewable Carbon concept.

Additional working groups have been created, one with a focus on communication, the other looking at the development of a renewable carbon label. In early September, a renewable carbon community will be launched as a starting point for even more interaction between the members, to discuss strategies, create new value chains and start project consortia.

The Renewable Carbon Initiative (RCI) is a dynamic and ambitious group of interested parties. Membership numbers have now more than doubled since the launch almost a year ago, with RCI now boasting 25 members, 6 partners and over 200 supporters. It welcomes all companies that are on the way to transform their resource base from fossil to renewable.

Outdoor apparel company Patagonia and circular fashion and textile technology group Infinited Fiber Company have signed a multiyear sales agreement for Infinited Fiber Company’s unique, premium-quality regenerated textile fiber Infinna™, which is created out of textile waste. The move marks a major milestone for both companies towards making textile circularity an everyday reality: The deal guarantees Patagonia access to the limited-supply fiber over the coming years and secures future sales income for Infinited Fiber Company as it ramps up production.

Infinna is a unique, virgin-quality regenerated textile fiber with the soft and natural look and feel of cotton. It is created from cotton-rich textile waste that is broken down at the molecular level and reborn as new fibers. Because it’s made of cellulose – a building block of all plants – Infinna is biodegradable and contains no microplastics to clog our seas. Clothes made with it can be recycled again in the same process together with other textile waste.

In April, Infinited Fiber Company announced plans to build a flagship factory in Finland to meet the growing demand for Infinna from global fashion brands. It is currently supplying customers from its R&D and pilot facilities in Espoo and Valkeakoski, Finland. The planned flagship factory will have an annual production capacity of 30,000 metric tons, which is enough fiber for roughly 100 million T-shirts made with 100% Infinna. Infinited Fiber Company expects to have sold the new factory’s entire output for several years during 2021.

More than 92 million metric tons of textile waste is produced globally every year and most of this ends up in landfills or incinerators. At the same time, textile fiber demand is increasing, with Textile Exchange estimating the global textile fiber market to grow 30% to 146 million metric tons by 2030 from 111 million metric tons in 2019. Infinited Fiber Company’s fiber regeneration technology, which uses cellulose-rich waste streams as its raw material, offers a solution both to stop waste from being wasted and to reduce the burden of the textile industry on the planet’s limited natural resources.

• Excellent project to encourage ingenuity among young students
• Experiment on biodegradability of textiles and nonwovens produces impressive results
• EUR 30,000 in prize money for a total of 209 participating schools in and outside Austria
• Lenzing views supporting these kinds of projects as part of its sustainability mission

Lenzing – The Association of Chemistry Teachers in Austria – known by its German abbreviation, VCÖ – has been holding project competitions that thrill students and take them beyond the traditional syllabus for 30 years. Every two years, it highlights a key topic for ninth- and tenth-graders to explore by conducting special experiments and learning from their observations and conclusions.

This year, the 16th installment of the competition is called, “Achieving a cleaner climate and a circular economy with chemistry”. These topics are also near and dear to the heart of globally active fiber manufacturer Lenzing. That’s why the company promptly announced that it was prepared to support this project competition in several different ways. First, Lenzing made a contribution toward the sponsorship fund totaling EUR 30,000. Second, it initiated a special prize on biodegradability – a topic of growing importance given the huge challenges involved in reducing plastic waste. Finally, Lenzing placed a recognized expert at the students’ disposal to provide assistance and answer questions: Michaela Kogler, Project Manager Nonwovens & Technical Products.

Teaming up with rainworms

Two teams were tasked with biodegrading different fibers – just like those used to produce textiles and nonwovens – with the active participation of worms. Students at BRG solarCity in Linz buried fiber nonwovens, a basic material used in wet wipes and other products, in soil that was populated with numerous rainworms, while students at Vöcklabruck Junior High School for Sports and Integration layered textiles into a vermicomposting bin. Both experiments intended to determine the extent to which certain materials would biodegrade quickly. As it turned out, both projects showed that wood-based fibers, like those that Lenzing manufactures for the textile and nonwoven industry, break down very rapidly into natural constituents that swiftly pass into the soil. In contrast, fossil-based plastics such as polyester or polyethylene cannot be decomposed by worms or bacteria but remain in the soil, sometimes for hundreds of years.

The prizes for this year’s competition were awarded on June 11. The competition attracted entries from no fewer than 209 schools, including 11 from outside Austria. For more information on the projects and the winners, visit www.vcoe.or.at.

• Fraunhofer, SABIC, and Procter & Gamble join forces
• The Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE and its Institute for Environmental, Safety and Energy Technology UMSICHT have developed an advanced recycling process for used plastics.
• The pilot project with SABIC and Procter & Gamble serves to demonstrate the feasibility of closed-loop recycling for single-use facemasks.

Due to COVID-19, use of billions of disposable facemasks is raising environmental concerns especially when they are thoughtlessly discarded in public spaces, including - parks, open-air venues and beaches. Apart from the challenge of dealing with such huge volumes of essential personal healthcare items in a sustainable way, simply throwing the used masks away for disposal on landfill sites or in incineration plants represents a loss of valuable feedstock for new material.

“Recognizing the challenge, we set out to explore how used facemasks could potentially be returned into the value chain of new facemask production”, says Dr. Peter Dziezok, Director R&D Open Innovation at P&G. “But creating a true circular solution from both a sustainable and an economically feasible perspective takes partners. Therefore, we teamed up with Fraunhofer CCPE and Fraunhofer UMSICHT’s expert scientists and SABIC’s Technology & Innovation specialists to investigate potential solutions.”

As part of the pilot, P&G collected used facemasks worn by employees or given to visitors at its manufacturing and research sites in Germany. Although those masks are always disposed of responsibly, there was no ideal route in place to recycle them efficiently. To help demonstrate a potential step change in this scenario, special collection bins were set up, and the collected used masks were sent to Fraunhofer for further processing in a dedicated research pyrolysis plant.

“A single-use medical product such as a face mask has high hygiene requirements, both in terms of disposal and production. Mechanical recycling, would have not done the job”, explains Dr. Alexander Hofmann, Head of Department Recycling Management at Fraunhofer UMSICHT. “In our solution, therefore, the masks were first automatically shredded and then thermochemically converted to pyrolysis oil. Pyrolysis breaks the plastic down into molecular fragments under pressure and heat, which will also destroy any residual pollutants or pathogens, such as the Coronavirus. In this way it is possible to produce feedstock for new plastics in virgin quality that can also meet the requirements for medical products”, adds Hofmann, who is also Head of Research Department “Advanced Recycling” at Fraunhofer CCPE.

The pyrolysis oil was then sent to SABIC to be used as feedstock for the production of new PP resin. The resins were produced using the widely recognized principle of mass balance to combine the alternative feedstock with fossil-based feedstock in the production process. Mass balance is considered a crucial bridge between today’s large scale linear economy and the more sustainable circular economy of the future, which today is operated on a smaller scale but is expected to grow quickly.

“The high-quality circular PP polymer obtained in this pilot clearly demonstrates that closed-loop recycling is achievable through active collaboration of players from across the value chain”, emphasizes Mark Vester, Global Circular Economy Leader at SABIC. “The circular material is part of our TRUCIRCLE™ portfolio, aimed at preventing valuable used plastic from becoming waste and at mitigating the depletion of fossil resources.”

Finally, to close the loop, the PP polymer was supplied to P&G, where it was processed into non-woven fibers material. “This pilot project has helped us to assess if the close loop approach could work for hygienic and medical grade plastics”, says Hansjörg Reick, P&G Senior Director Open Innovation. “Of course, further work is needed but the results so far have been very encouraging.”

The entire closed loop pilot project from facemask collection to production was developed and implemented within seven months. The transferability of advanced recycling to other feedstocks and chemical products is being further researched at Fraunhofer CCPE.

Ahlstrom-Munksjö has expanded its portfolio of biodegradable and renewable fiber-based solutions for food packaging papers, receiving compostability certification from the Biodegradable Products Institute®.

Continuing to be at the forefront of sustainable product offerings, Ahlstrom-Munksjö’s FluoroFree® and ParaFree® food packaging papers produced in North America are now BPI® certified, in addition to offering multiple sustainability attributes in a single product.  

These certifications facilitate the possibility for Ahlstrom-Munksjö customers, whether converters or brand owners, to achieve their own sustainability goals. By using a scientific process, BPI officially certifies compostable products that meet ASTM D6400 and ASTM D6868 standards for compostability. BPI Certification proves that a material will compost in a commercial composting facility, leaving behind no toxic residue or microplastics.

In addition, Ahlstrom-Munksjö’s ParaFree® Wax Alternative papers have achieved BPI Certifcation; papers manufactured without the addition of paraffin or other petroleum-based materials. ParaFree® products create a more sustainable alternative to this type of widely used quick service restaurant packaging. These products maintain a high-level of performance and are stronger on a pound-for-pound basis, allowing for improved yield and lower transportation costs and reducing its overall impact.

• Demo plant sorts post-consumer plastic waste and will produce ready-for-market fully formulated polymer pellets
• Brand owners and converters will be able to access material for qualification and market validation in early 2021
• EverMinds™ in action: Pioneering collaboration brings together expertise vital to advancing the circular economy

Borealis and TOMRA have today announced the operational start of their advanced mechanical recycling demo plant in Lahnstein, Germany, the result of a partnership that marries chemistry with technology for unsurpassed results.

The state-of-the-art plant processes both rigid and flexible plastic waste from households. And unlike many current recycling plants, it will produce the advanced solutions necessary for use in high-demanding plastic applications in various industries, including automotive and consumer products. With high purity, low odour, high product consistency and light colour fractions, these Borcycle™ M grade recycled polymers will meet customer quality requirements across the value chain.

The purpose of this demo plant is to generate material for brand owners and converters to qualify, validate and prove fit for use in their highly demanding applications. Technical success will set the groundwork for a commercial-scale advanced recycling plant.

“This plant is just the beginning of what’s possible when key players in the value chain come together to make a truly significant impact in the market,” says Volker Rehrmann, Executive Vice President and Head of Circular Economy at TOMRA. “Having just launched the new Circular Economy Division, it is clear what a large role waste management and pivotal projects like this have on moving towards a sustainable future. We are proud to have initiated one of the most advanced mechanical recycling plants when it comes to post-consumer polymer waste. This will become an important enabler as we accelerate the transformation to a circular economy in the years to come, and we are excited to be a part of this pioneering project.”

Operation of the plant is a joint enterprise between Borealis, TOMRA and Zimmerman. Borealis is responsible for the plant’s commercial success and contributes its expertise and knowledge in innovation, recycling and compounding. Likewise, TOMRA contributes as a provider of technology-led solutions and brings its proven expertise, established process and market knowledge, which, in turn, enable the circular economy through advanced collection and sorting systems. Zimmerman is a waste management company with experience in sorting multiple types of waste, including plastics, and is responsible for successful plant operations and product quality.

“At P&G we are making packaging with the ‘next life’ in mind to help drive a more robust circular economy.  We must increase the supply of high quality recycled plastic to enable the industry to deliver on this vision,” says Gian De Belder, Procter & Gamble (P&G) Technical Director, R&D Packaging Sustainability. “The innovative new approach that Borealis is taking shows potential to step-change both the quantity and quality of PCR available for our brands, and help us to achieve our 2030 goal to reduce our use of virgin plastic in packaging by 50%, or 300 kilotonnes annually. Early tests of the material looks very promising!”