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