Sustainable Plastics - October 2021 - 14

opinion
Five rules for plastic
processors: Using recycled
materials sustainably
There's a steadily growing demand for more environmentally friendly products.
Politicians are also calling for much higher quotas for the use of recycled material.
Plastics processors are therefore already facing fierce competition for sufficient
quantities of high-quality recycled materials. Not just procurement is a challenge for
manufacturers; processing the recycled material also calls for in-depth expertise.
Marc Stachura, Director of Product Management Recycling at Meraxis, lists five
rules for a successful use of recycled material.
I
n the European Union, almost
23 percent of plastic
packaging must be
recyclable, according to
the EU's Circular Economy Action
Plan. By 2030, the quota will
be raised to 55 percent - more
than twice as high. Thus plastic
producers must now step
up their game and use more
recyclates. The problem with
this: There's often not enough
high-quality recycled material
available due to decentralised
market structures. This causes
shortages of raw materials and
price fluctuations. So let's take
a closer look at important rules
plastics processing industries
should follow to ensure the use
of recycled materials succeeds.
Rule 1: Secure the best
sources
For processors, finding the right
supply partner can be hard. They
need to have an in-depth knowledge
of the market, and ideally,
examine potential suppliers or
even conduct extensive audits
to ensure that the raw materials
are actually processed in the desired
quality and quantity. This
approach is especially costly for
small and medium-sized enterprises.
The research is time-consuming
and requires technical
knowledge about the production
of recycled materials. Working
with a distribution partner who
specialises in the procurement
of prime and recycled material
and has access to a worldwide
logistics and distribution network
can make the process easier. Unlike
pure recyclate manufacturers
14
October 2021
who can only supply what they
currently produce, such distributors
typically have a tight network
of audited supplier partners for
regranulates and recompounds.
This enables plastics processors
to ensure that they actually receive
recyclates in the necessary
quantities and at the best quality.
A supplier that also offers prime
material has another advantage:
there is a broad portfolio available
for any application with the
desired materials. In addition,
suitable alternatives can be selected
quickly in the event of supply
bottlenecks.
Rule 2: Pay attention to
material properties
When processing secondary material,
processors need to make
sure that the recyclates have a
similar quality to the prime material
that was used previously. However,
because recyclates naturally
differ from one another depending
on their origin, different batches
are homogenized. This means
that they're mixed, so that large
quantities of consistent quality
are produced. Precise testing and
initial sampling are essential because
recyclates from different origins
differ in terms of properties.
This initial testing is a technical
process for material characterisation
that precisely tests whether
recyclates are suitable for the intended
use.
Rule 3: Develop the right
formulation
Material development starts with
a detailed definition of the technical
properties. The proportions
of recyclates, prime materials
and other ingredients must be
matched with each other in line
with the application. This needs
to be done because the requirements
of the product differ depending
on the application. Additives
can be used as needed
to improve the properties. When
selecting a supplier, processors
should therefore ensure that their
suppliers are able to develop such
formulations based on the specific
application. This allows processors
to match their requirements
directly with the distributor.
Rule 4: Select the appropriate
production
processes and machines
It's also important to match process
technologies, tools and the
right materials. The parameters
of production machinery - such
as material throughputs, cycle
times or processing temperatures
- must be set individually
for each material to prevent
faulty production. This is especially
true when recycled materials
are used: Processors should
use the most homogeneous raw
material mass possible during
production, so that it stays constant
throughout the production
process. Ideally, this means that
only one basic adjustment needs
to be made to the machine.
Processors should make sure
that the distributor offers comprehensive
technical services
as well as on-site support. Technical
experts should help select
the most efficient production
processes and tools, and set individual
parameters correctly to
achieve the desired result.
Rule 5: Demonstrate
sustainability
The interest in products that
are as environmentally friendly
as possible has increased
significantly, especially among
consumers. The use of recycled
materials has long been an
additional sales and marketing
argument. That's why it may be
advisable to indicate on the end
product that recyclates were
used. Recognised certificates
such as EuCertPlast are suitable
for this purpose. EuCertPlast
is an EU-wide certification
programme that focuses on the
traceability of plastic materials
throughout the recycling process
and supply chain.
Conclusion
The use of recycled materials
must be well thought out. It requires
extensive process engineering
know-how. But in the
end, it is worth it, as it brings the
polymer industry a big step closer
to a closed-loop economy.
www.meraxis-group.com
Marc Stachura
http://www.meraxis-group.com
Sustainable Plastics - October 2021

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