The market and properties of recycled plastics Peter Farrow Sales Manager, Ravago Manufacturing Europe 8 th October 2020
The market and properties ofrecycled plastics
Peter Farrow
Sales Manager, Ravago Manufacturing Europe
8th October 2020
CONTENT
• Circular Economy for Plastics
– Timeline and Status
– Strategy for Plastics
– Pledge Examples
– Industry Responses
• Ravago Manufacturing Europe
– Capability
– Process
• Applications for Recycled Material
– PP
– PA
– PC/ABS
• Conclusions
Circular Economy: Timeline and Status
2015: Circular economy action plan adopted putting the EU economy on a sustainable path to deliver the UN
Sustainable Development Goals
2017: EU confirmed it would focus on plastics production and work towards
ensuring all plastic packaging is recyclable by 2030
Jan 2018: EU invites stakeholders to submit voluntary pledges to use or
produce recycled plastics. Communication issued by the EU on
actions on the plastics strategy moving forward
Early 2019: Pledges assessed, EU report written, and Circular Plastics
Alliance (CPA) formed. Declaration of the CPA released in September 2019
EU Plastics Strategy was a
key priority of this action
plan and to consider the
whole value chain and
lifecycle of the plastic part
Action plan defined.
Target is 10 million
tonnes of recycled
plastics to find their way
into products by 2025
2015 2017 2018 2019
What is the strategy?
Voluntary pledges?
Key actions?
Industry responses?
Packaging and
Packaging Waste
Directive
Circular Economy: Strategy for Plastics
In March 2019, the assessment report of the company and industry pledges found that:
• suppliers of recycled plastics pledged that 10 million tonnes could be delivered to the EU
market in 2025
• buyers of recycled plastics pledged that 6.4 million tonnes could be used in their products in
the EU in 2025
The formation of the Circular Plastics Alliance is intended to promote voluntary actions and
commitments from all stakeholders to overcome this projected shortfall in demand from
convertors and brand owners of 3.6 million tonnes in 2025
In 2018, the EU listed a range of measures to implement the plastic strategy section of the
Circular Economy with a subset of actions focused on plastics:
• Improving the economics and quality of plastics recycling
• Actions to improve product design• Actions to boost recycled content • Actions to improve separate collection of plastic waste
Circular Economy: Pledge Examples
Kärcher will push forward the use of recycled plastics in Kärcher products. For example through
the usage of several 100 tons/year of ECO-PA (recycled material from airbag production) for the
production of Kärcher-accessories.
HP used more than 4,500 tonnes (10 million pounds) of recycled plastics in the 28 EU countries
in 2017. HP intends to grow the amount of recycled plastic content (RCP) used by more than
50% by 2020; and intends to use a total of 22,500 tonnes (50 million pounds) of recycled
plastics in the 28 EU countries in its products from 2017 to 2020 inclusive.
Miele & Cie KG is pledging to use 5,000 – 7,500 tons of recycled plastics by 2025. PP and ABS.
Plastic Recyclers Europe pledged that the 10 million tonnes will be supplied to increase the use
of recyclates in plastic products by 2025. This will be possible through the achievement of
specific measures that must impact mostly:
1.Design for recycling for plastic products
2.Increased quality collection and sorting
3.Financial incentives https://circulareconomy.europa.eu/platform/en/commitments
https://circulareconomy.europa.eu/platform/en/commitments
Circular Economy: Key Industry Responses• By 2030 all plastic packaging within the EU will need to be recyclable or reusable. Flexible packaging
produced from monomaterials can support this objective.
• The simplification of flexible packaging design by using only polyolefin materials makes the collection,
sorting and recycling process more efficient.
• Food contact approval for recycled plastics remains challenging.
• Construction Products Regulation and the resulting CE marking requires further review to enable recycled
plastics to be used in regulated products.
• Plastics convertors and trade associations focus on the energy efficiency and durability of using prime
quality plastics over other materials (such as metal) during the use phase.
• Plastics used in construction (over a significant lifetime) can be recycled but not necessarily re-designed
back into construction applications.
• Mandatory Targets for Recycled Plastic Content are not Meaningful for Vehicles
• However ACEA members (as part of the Circular Plastics Alliance) are voluntarily committed to increasing
the level of recycled plastic content in their vehicles
• The concern ACEA members have is the quality level available and the supply demand balance and affect
on recycled plastic pricing over the whole production period of a vehicle
• Behind PolyCE there are 20 expert organisations from nine countries that are working together to
significantly reduce the use of virgin plastics and enhance the use of recycled plastics in new electronics
applications
• According to the Nordic Council of Ministers, plastics account for about 20% of all materials in electronic
and electrical equipment (EEE), and most of it not designed for recovery and reuse.
• The PolyCE consortium is launching a two-year campaign starting in November 2019 to raise awareness
among consumers and manufacturers in order to change their attitudes towards recycled plastics and
improve their market uptake.
Contribution of Ravago Manufacturing Europe
Arendonk (BE)
Schkopau (DE)
Steinfurt (DE)
Vilallonga (ES)
Locate (IT)
Mornico (IT)
Salerno (IT)
Izmir (TU)
Istanbul (TU)
PE Ravalene®
PP Scolefin®
PP Verplen®
PP Ravaplen®
PP Mafill®
PS Sicostirolo®
PA Ravamid®
PA Hylon®
ABS Sicoflex®
ASA Polyfast®
PA-ABS Sicoblend®
PC Sicoklar®
PC-ABS Mablex®
PC-ASA Mablex SA®
TPE-V Enflex®
TPE-V Ezprene®
TPE-S Ensoft®
TPE-S Sconablend®
TPE-U Ravathane®
• Quality
• Product
portfolio
• Operations
• Supply chain
for recycled
feedstock
RAW MATERIAL ARRIVAL
CONTROL CHECK @ GATENO
REJECTED
YES
UNLOADING AND IDENTIFICATION
SAMPLING @ 100%LAB CHECKS
VISUAL INSPECTION
EXTRUSION
INJECTION
CHARATERIZATION (INCLUDING FT-IR)
EVALUATION VS. SPECS
NO
REJECTED
YES
RAW MATERIAL PREPARATION & HOMOGENIZATION
FINAL TESTING AND VALIDATIONBATCH UNLOCKED FOR USE IN PRODUCTION ACCORDING TO FORMULATION
Process Flow
POLYPROPYLENE RECYCLED COMPOUNDS
PROPERTY COMPARISON: UNFILLED PP
Property Mafill CR C
5044
Prime PP-C 1 Mafill CR CE
5044
Prime PP-C 2
Product
Description
PP-C IQ Black Virgin PP-C
Natural
PP-C IQ Black Virgin PP-C
Natural
Density ( g/cm3 ) 0.95 0.90 0.93 0.90
MFI
(230°C / 2.16
Kg)
10 12 8 11
Charpy Notched
Impact 23°C
(kJ/m2)
11 10 39 27
Flexural Modulus
(MPa)
1100 1450 900 1200
Comparison of Mafill recycled unfilled black PP compounds with virgin prime PP-C natural grades
PROPERTY COMPARISON: PP TALC FILLED
Property Mafill CR CT 5344H Scolefin 52T 10-9
Product Description PP-C IQ 20% TF Prime PP-H 20%TF
MFI
(230°C / 2.16 Kg)
11 12
Izod Notched Impact
23°C (kJ/m2)
7 3
Flexural Modulus
(MPa)
1900 2300
Tensile stress at yield
(MPa)
22 32
HDT/A (°C) 55 60
Property Mafill CR CT 5644H Scolefin 54 10-9
Product Description PP-C IQ 40% TF Prime PP-H 40%TF
MFI
(230°C / 2.16 Kg)
10 15
Izod Notched Impact
23°C (kJ/m2)
4 2
Flexural Modulus
(MPa)
3500 4000
Tensile stress at yield
(MPa)
24 30
HDT/A (°C) 65 90
Comparison of 20% and 40% talc filled black Scolefin prime and Mafill recycled PP compounds
PP-C feedstock for IQ compounds is more readily available than PP-H feedstock. However mechanical and
thermal properties can still be sufficient for PP-C IQ to replace prime PP-H compounds bringing significant cost
saving opportunities.
GRADE: MAFILL CR CT 5344 HECU tray electric adapter (seating trims)
• Replacement of prime material
• Cost benefit to the supply chain and OEM
• Good mechanical and flow properties
• Excellent processability
GRADE: MAFILL CR HT 6344 HBumper reinforcement bar, guide profiles and other applications requiring VW 44045-PP6 from a
20% talc filled PP-H black recycled content compound
• Fully approved by SKODA (VW44045-PP6)
• Replacement of prime material
• Cost benefit to the supply chain and OEM
• Tailored mechanical and flow properties
• Excellent processability
GRADE: MAFILL CR HT 6344 U UV E25015Cowl vent grill for the VW T-Cross moulded from a scratch and mar
resistant, UV and heat stabilized, coloured matched 20% talc filled PP-H
black recycled content compound
• Track record within VAG for cowl vent grill on
other vehicles
• Cost saving versus prime grades specifically
designed for this application
• Capability to colour match Mafill to automotive
black exterior colours
• High UV stabilization packages developed for
PP recycled content compounds
• Balancing a range of key properties – impact,
flexural modulus, thermal performance
(HDT/B)
RAVAPLEN NEAR PRIME PP COMPOUNDSRavaplen grades contain both prime and recycled PP are optimised for surface finish, scratch
resistance, low odour, fogging and emissions, excellent processability (high MFI) and improved
economics versus 100% prime. Interior or exterior applications.
Ravaplen grade names are:
• 33H 40-9 (Hybrid)
• 62 T 40-9 (T16)
• 51 T 45-9 (T10)
• 62 T 42-9 (T16)
• 71 T 44-9 (T10)
• 72 T 45-9 (T20)
• 72 T 43-9 (T20)
Only colour
matched dark
grey or black
options are
available
PROPERTY COMPARISON: PP GLASS FILLED
Property Scolefin 33G 10-9 Scolefin 53G 13-9 Mafill CR XG 3544H Mafill CR XG 5544H Mafill CR XG 5544M
Product Description Prime PP-H 30%GF Prime PP-H 30%GF PP-C IQ 30% GF PP-C IQ 30% GF PP-C IQ 30% GF
MFI
(230°C / 2.16 Kg)
4 13 7 10 10
Izod Notched Impact
23°C (kJ/m2)
12 10 10 10 8
Flexural Modulus
(MPa)
5500 6700 5700 6100 4500
Tensile Modulus
(MPa)
7000 6500 6000 6300 2700
Tensile stress at
yield (MPa)
80 85 80 80 55
HDT/A (°C) 140 150 141 145 130
Comparison of 30% glass filled black prime and recycled PP compounds. Variety of performance
required for differing price levels.
GRADE: MAFILL CR XGE 5544 BLACK Municipal container arm moulded from impact modified, 30% glass fibre filled
PP black recycled content compound
• Approval process driven by waste
management company and moulder
• External laboratory test program
• Tailor made grade for this specific application
• Replacement of prime material with the
recycled product meeting all specification
requirements – impact being the most critical
The bins in our new range are eco-designed and manufactured completely from recycled plastics. They are easily repairable to extend their useful life and are recycled at end of life. This is the result of several years of commitment by SULO, whose expertise is now unique in Europe.
ENGINEERING THERMOPLASTIC
RECYCLED COMPOUNDS
Sicoflex ECO® ABS
•MZ341 general purpose
•GF17 17% GF
Sicoklar ECO® PC
•UG25 general purpose
•UG10FV 10% GF
•UG81.15 FR V0
•UG58.10 10%GF-FRV0
Mablex ECO® PC/ABS
•PCX general purpose
•PCA medium heat
•PCB high impact
•GF10IQ 10% GF
•GF20IQ 20% GF
•GF30IQ 30% GF
Ravamid® B (PA6) & A (PA66)
•B BK45 PA6 unfilled
•B (T or ST) BK45 impact modified
•B GFXX BK45 from 10 to 50% GF
•A BK45 PA66 unfilled
•A (T or ST) BK45 impact modified
•A GFXX BK45 from 10 to 50% GF
Recycled portfolio - ISO 14021 : 2016
ECO RECYCLED SOLUTIONS
✓ Unfilled
✓ Glass filled
✓ Hybrid solution
✓ Impact modified
• Superior properties vs. post consumer solutions
• European sources of feedstock ensure an effective control of the composition
and traceability of the feedstock being purchased – critical for consumer
products
• Polymer producers, compounders and convertors are required to produce in
accordance with European legislation such as RoHS
• Consistent processability and quality due to feedstock selection and then
classification
Large grade portfolio with the ECO
material as the base resin is possible=>
Feedstock examples
PROPERTY COMPARISON: PA 6 AND PA 66
Property Ravamid A
ST BK45
Competitor 1 Ravamid B
GF30 H BK45
Competitor 2 Ravamid A
GF35 H BK45
Competitor 3
Product
Description
PA66 IQ
Impact modified
PA66 Prime
Impact modified
PA6 IQ 30% GF
Heat stabilized
PA6 Prime 30% GF
Heat stabilized
PA66 IQ 35% GF
Heat stabilized
PA66 Prime 35% GF
Heat stabilized
Density ( g/cm3 ) 1.09 1.10 1.35 1.36 1.41 1.41
HDT/A (°C) 60 70 205 200 235 250
Izod Notched
Impact 23°C
(kJ/m2)
13.5 18.0 8.5 10.0 8.5 12.0
Flexural Modulus
(MPa)
2200 2280 7800 8500 8300 10500
Tensile Modulus
(MPa)
- - 8600 9500 8700 11200
Tensile stress at
break (MPa)
- - 132 170 155 200
Tensile stress at
yield (MPa)
50 64 - - - -
Comparison of unfilled and glass filled black prime and recycled PA6 and PA66 compounds
GRADE: RAVAMID A GF30 H BK45
• Heat stabilized PA66 GF30 IQ grade
• GM Opel approved and commercial with VAG for fan shrouds
• Specification and recycled feedstocks defined
• Moldflow characterization completed
• Replacement of prime grades
Specification Method Unit of
Measure
Minimum Maximum
MFI 275°C/ 5 Kg g/10min 40 60
Density ISO 1183 g/cm3 1.34 1.36
Tensile Modulus ISO 527 MPa 7100
Tensile Stress
at Break
ISO 527 MPa 121
Izod Notched ISO 180,
23°C
kJ/m2 7
Ash ISO 3451,
800°C
% 28 32
Viscosity
Number
ISO 307 g/cm3 125 150
PROPERTY COMPARISON: PC/ABS
Property Mablex ECO PCX Mablex ECO PCA Competitor 1 Mablex ECO PCB Competitor 2
Product Description PC/ABS IQ PC/ABS IQ PC/ABS Prime PC/ABS IQ PC/ABS Prime
MFI
(260°C / 5 Kg)
30 26 18 20 19
Izod Notched Impact
23°C (kJ/m2)
25 40 48 50 48
Flexural Modulus
(MPa)
2300 2400 2350 2400 2300
Tensile Modulus
(MPa)
2300 2400 2350 2400 2300
Tensile stress at
yield (MPa)
45 50 54 53 54
Vicat B50 (°C) 120 120 118 125 128
Comparison of unfilled black prime and recycled PC/ABS compounds
MABLEX ECO UNFILLED PC/ABS COMPOUNDS
MFI IZOD VICAT
27.72 51.20 123.9026.10 50.20 123.3232.18 50.25 125.0031.70 52.25 124.5829.80 48.18 125.0027.80 56.10 124.8828.25 52.23 123.2323.13 39.25 124.0023.13 48.00 123.4028.00 53.80 124.5024.60 52.53 120.6030.50 50.50 124.6330.75 53.13 124.3827.80 50.80 122.8032.40 53.20 123.8028.60 51.20 125.0028.50 50.00 125.0024.00 44.20 125.0026.20 43.00 125.0031.70 52.25 124.5829.80 48.18 125.0027.80 56.10 124.8828.25 52.23 123.2331.70 52.25 124.5829.80 48.18 125.0027.80 56.10 124.8828.25 52.23 123.2323.13 39.25 124.0023.13 48.00 123.4028.00 53.80 124.5026.20 43.00 125.0031.70 52.25 124.5832.40 53.20 123.8028.60 51.20 125.00
• MFI, Impact and Vicat on each certificate of analysis.
• Produced at two Ravago production plants for security of
supply.
• Main grade is Mablex ECO PCA S25000. Full Moldflow
characterization is available.
• Covered seat parts and door sets are common automotive
applications.
• Non-visible interior brackets behind infotainment.
GRADES: MABLEX ECO PC/ABS TYPESMiddle console arm rest top cover made from PC/ABS IQ
materials. Grade selection depends on the impact
performance required from different Automotive OEM’s.
• Recycled PC/ABS for covered parts
• Approved at VW and FORD
• Commercial benefits versus prime
• Low VOC emissions and fogging
• Excellent consistency in properties
• Can be considered for other covered
or non-visual interior parts – seat
backs, armrests, door substrates and
brackets
VW Golf Plus VW379
Ford Focus C519
CONCLUSIONS
• The core activity of Ravago for nearly 60 years is recycling plastic waste,
preventing material going to landfill and incineration
• Ravago is aligned with the Circular Economy Action Plan, EU Plastics Strategy, a
member of PRE and the Circular Plastics Alliance (CPA)
• Ravago is actively involved in the major industries committed to achieving the key
subset of actions in the EU Plastics Strategy:
• Improving the economics and quality of plastics recycling
• Actions to improve product design• Actions to boost recycled content • Actions to improve separate collection of plastic waste
• Ravago has extensive recycled plastic compound application knowledge to find
practical solutions and increase the level of recycled plastic use