More Sustainable Plastic Applications: Polycarbonate Recycling, Material Reduction and Bio-Based Plastics

The new EU End-of-Life Vehicles Regulation is increasing pressure on the automotive industry to keep plastics and other materials in the loop for longer. At the same time, composite materials, long product life cycles and strict quality requirements make implementation challenging. Three examples show the role that material selection, vehicle design and recycling can play.

Polycarbonate components from municipal street lighting systems present particular challenges for material recycling. End-of-life covers are still mostly incinerated or sent to landfill. Trinseo and Signify are therefore pursuing an approach that keeps the material in circulation within the same application.

The components are collected in the Netherlands and processed by Trinseo using its dissolution technology. This produces a polycarbonate compound containing 75% recycled content while meeting defined requirements for color and light transmission. Signify myCreation then converts the material into filament for the 3D printing of new pendant lampshades. This makes it possible to reuse a previously difficult-to-recycle polycarbonate waste stream for new lighting applications.

Alongside recycling, reducing material consumption is another approach to improving sustainability.  Jokey has developed the JSLB 1090, a one-liter container weighing just 30 grams, including the lid.

The packaging:

• is made entirely from mono-material polypropylene
• is fully recyclable
• is based on the company's proprietary ThinWall technology, which enables thinner wall sections while maintaining functionality

According to the company, the container continues to meet the requirements of industrial filling, transport and logistics processes. The approach: reducing material use while maintaining functionality.

ALPLA and BIOGENA are pursuing another approach to more sustainable plastic applications. Together, the companies have developed a packaging solution made from bio-based polyethylene (Bio-PE), produced from residues generated during sugarcane processing.

The packaging is designed for the HDPE recycling stream and was developed with a focus on product protection, transport efficiency and ease of use. The aim was to create packaging that is recyclable while also contributing to lower CO₂ emissions. The approach combines bio-based raw materials with a recyclable packaging concept and demonstrates another way of partially replacing fossil-based raw materials.

The three examples illustrate the wide range of approaches currently being pursued to improve sustainability in the plastics industry. Closed material loops, material reduction and bio-based raw materials represent different strategies, while equally contributing to a more resource-efficient use of plastics. Together, they reflect developments that are shaping international industry discussions and are regularly showcased at K.

Author: Sofia Vallejo