Decarbonisation in the Plastics Industry: CO₂-negative Materials for Industrial Use

Sustainability and innovative materials are two key topics in modern plastics processing. The collaboration between the mechanical engineering company Arburg and the industrial raw materials start-up carbonauten promises exactly that: CO₂-neutral and even CO₂-negative masterbatches and compounds for industrial applications.

In an interview with K-Mag, Torsten Becker from carbonauten and Manuel Witte from Arburg talk about the background to the cooperation, the technology behind the new materials, their processing in the injection moulding process and the prospects for the future.

How did the collaboration between Arburg and carbonauten come about?

Torsten Becker: It started indirectly via LinkedIn. I came into contact with a natural charcoal burner in the Black Forest who produces gourmet barbecue charcoal. In the course of our discussions, an event was mentioned – the CarbonX week as part of the Freudenstadt Baiersbronn Garden Show – which is supported by Arburg. Finally, we met with Arburg representatives. Manuel Witte was already there at the time. And it quickly became clear that we had a shared vision. This led to the first tests and finally to the co-operation.

How did Arburg view the initial talks and the possibility of working together?

Manuel Witte: For us as a company, sustainability is an essential topic. We bundle all our activities in our 'arburgGREENworld' programme and are always on the lookout for new materials and technologies that can help conserve resources and reduce the CO₂ footprint. That's why the project was very exciting for us right from the start.

Our aim is to ensure that the materials can be processed safely and precisely on standard machines. Arburg's decades of experience with sustainable materials is a huge help here.

Can you explain exactly how the material production process works?

Becker: Our masterbatches and compounds, which we develop in cooperation with Arburg, are CO₂-negative. This means that they store more CO₂ than they emit during their production and use. The basis of these materials is technical biocarbon, which is obtained from plant residues – in our case, lumpy wood residues. Pyrolysis converts these into a stable carbon form that is used as an additive in plastics. The result is a material that is not only measurably more sustainable, but also mechanically stable and versatile.

What makes this material special compared to conventional plastics?

Becker: The big advantage is not only the CO₂ storage, but also the improved material properties. It is harder, stronger, more temperature-resistant, more UV-resistant, more dimensionally stable, lighter, replaces carbon black and can optimise the processing of recycled plastics as an additive. In addition, 30-50% of the polymer is avoided, which has a significantly positive effect on Scope 3 and the overall ecological balance. The most important point is that it is no more expensive than conventional fossil-based materials – in some applications it is even cheaper.

What specific applications already exist for this material?

Becker: Deutsche Bahn, for example, supplies us with waste wood from pallets and railway sleepers. These materials are no longer disposed of or incinerated, but integrated into our process. This results in new components that can then be reused in industry. Demand from the EU automotive sector is now increasing enormously.

How is the industry accepting this material? Is there any scepticism regarding the quality or processing?

Witte: It is true that processors often have reservations about new materials. However, we have specifically ensured that the compounds can be processed on standard injection moulding machines without the need for additional special equipment. This makes it easier for companies to process these materials and integrate them into their portfolio.

What about production capacity? Are there already larger production facilities?

Becker: Our first production facility in Eberswalde is ready for operation, but has not yet been fully optimised. The capacity is currently around 3,000 to 3,500 tonnes of carbon per year, which results in around 6,000 to 9,000 tonnes of compound. However, we need further investment for the full ramp-up. We are currently in financing rounds to drive forward this optimisation and expansion.

Are there plans for international expansion?

Becker: Yes, especially in China. We want to build a large factory there that produces biocarbon from waste bamboo. The planned plant will have a capacity of 30,000 tonnes of carbon and 90,000 tonnes of compound per year. The project is currently in the financing phase.

The cooperation between Arburg and carbonauten shows what sustainable innovation in the plastics industry can look like. The use of biocarbon creates materials that are not only CO₂-neutral, but even CO₂-negative. The coming years will show how these new materials establish themselves in industry and what further developments will emerge from this collaboration.