MATERIALS | RECYCLED PLASTICS
supplier Hella – which also includes Covestro, BMW, Geba Kunststoffcompounds, the Fraunhofer Institute for Mechatronic Systems Design IEM, the Heinz Nixdorf Institute, and Hamm-Lippstadt University of Applied Sciences – aims is to optimise sustainability throughout the entire life cycle of a vehicle. The research project, called NALYSES, which started in October 2022, is designed to last three years and is funded by the German Federal Ministry of Education and Research. Central to the project is the development of a sustainable car headlamp, which incorporates recycled materials. Borealis says that around 150,000 tonnes/yr of
Above: The Genbeta electric race car includes recycled
thermoplastics from SABIC
ered as part of the overall material matrix – as filler for example,” says Benvic. “PVC recyclate is a great candidate in this respect. One ultimate target would be to integrate a recycled PVC matrix with recycled or bio-based fillers for applications in agricultural or construction sectors.” In addition to Benvic’s base business in PVC compounds, other group materials are also the subject of recycling development work, including DotCore PP and DotFlex TPEs. The company says it is working closely with its current customers, to custom manage the shift towards recycled materials. Applications with recycled content are making a name for themselves on the big stage. In July, the Genbeta electric car developed in connection with Formula E racing, which includes recycled thermo- plastics from SABIC, set a new Guinness World Record for the fastest speed achieved indoors of 135.9 mph. SABIC’s role in the programme, which is aimed at exploring new materials and technolo- gies for future EV race and road cars, is part of its collaboration with the world’s first all-electric FIA World Championship. Compared to other alterna- tives, the SABIC materials enable more design freedom through their inherent processing mouldability. The Genbeta’s Wheel fins are injection moulded with SABIC’s mechanically recycled thermoplastics from its Trucircle circular materials.
As for the volume automotive market, SABIC says it is targeting instrument panels, front end modules and tailgates with its mechanically recycled Stamax PP copolymer which contains postconsumer waste. A consortium led by automotive
Right: The Nalyses project is looking at how products and raw materials can be reused as long as possible in a circular economy, focusing on the example of a sustainable car headlamp
14 INJECTION WORLD | September 2023
www.injectionworld.com
products they currently manufacture in Europe are circular. These include recycled and renewable polymers and chemicals as well as renewable hydrocarbons. The company says: “We use mechanical recycling to make products with the highest possible value and quality, and continue looking into developing newer technologies for mechanical recycling with partners with the sole objective of delivering products of the highest quality. Borcycle M is our transformational ad- vanced mechanical recycling technology driving the transition to a circular polyolefin industry by creating highest quality materials in the most energy efficient way. The technology is ever-ad- vancing, using value chain collaboration and Borealis’ expertise and experience to unlock the potential of recycled material in ever-more de- manding applications.” In October 2022, Borealis announced a signifi-
cant expansion with the construction of a new commercial-scale advanced mechanical recycling plant in Austria with a capacity of over 60,000 tonnes/yr. In June this year it agreed to acquire Italian company Rialti, a leading producer of mechanically recycled PP compounds for injection moulding and extrusion. Producers of engineering plastics have also
made progress with recycled material develop- ments. Domo Chemicals has received, for the first time in the polyamide industry, the UL RTI electrical rating on a mechanically recycled sustainable PA66. The new UL card file E44716 was published on 24 April, and certifies an RTI
IMAGE: SABIC
IMAGE: COVESTRO
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