The SPE Library contains thousands of papers, presentations, journal briefs and recorded webinars from the best minds in the Plastics Industry. Spanning almost two decades, this collection of published research and development work in polymer science and plastics technology is a wealth of knowledge and information for anyone involved in plastics.
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Recycling
Various topics related to sustainability in plastics, including bio-related, environmental issues, green, recycling, renewal, re-use and sustainability.
Post Consumer Recycled Plastics in Electronic Products
Closed Loop Inkjet Cartridge; Recycling Program: – Cartridges torn down and 100% recycled – Recycling/Cleaning partners – PPO/PS resin is collected – Cleaned and recompounded – Compounding partners – Reintroduced into new ink cartridges
Removing Barriers to Create a Better World
All manuf. sites will have a wildlife habitat certification or
equivalent (where feasible) • GM will utilize 125 MW of renewable energy sources • Reduce energy intensity by 20% (baseline 2010) • Reduce carbon intensity by 20% (baseline 2010) • Reduce total waste by 10% (baseline 2010) • Reduce water intensity by 15% (baseline 2010) • Reduce VOC intensity by 10% (baseline 2010) • 100 mfg. sites and 25 non-manufacturing sites are landfillfree
Marine Biodegradation of PLA, PHA, and Bio-additive Polyethylene Based on ASTM D7081
Topics: Introduction • Marine Pollution • Biodegradable Plastics Definitions • Biodegradation Results: – Compost testing – Marine testing • Conclusions
Improved Recycling of Difficult to Process Materials.
Common Issues With Recycling Heavily Printed Materials: Printing inks contain binders and additives that emit gases when heated to required melt temperatures. Gases and other contaminants enter melt and
often result in poor quality pellets.
A Comparison of Technologies to Recycle Mixed and Dirty Plastics
US EPA waste plastics data show that in 2010: A total of 31 million tons of plastic waste was generated making up 12.4 % of total MSW. Only 8 % of this waste was recovered for mechanical recycling. The rest most likely goes to landfills as dirty and soiled plastic.
Comparative Life Cycle Assessment (LCA) of Bio-Fibers, Mineral and Glass Fiber Reinforced Polypropylene Composites
Embodied energy values were determined for bio-fibers, mineral and glass fiber using data
obtained from recently published technical papers. This data, together with other LCA and
actual physical property data was used to explore the comparative performance and
environmental footprints for a wide range of reinforced polypropylene composites. The data
show that RheVision® bio composite materials present competitive and useful physical
performance coupled with improved environmental impacts.
Unique Performance Characteristics of New, Durable, Biobased Polyamide and Copolyester
Plant oil based derivatives have been noted in polymer chemistry dating back to the fist
developments of polyamides in the 1940's. In the world of elastomers, natural rubber has
always been plant based. Today the use of bio mass derivatives has gained new attention given
the quest to reduce the dependence of polymer production on petroleum sources. One notable
monomer is sebacic acid derived from caster oil and used in polyamides. The advantage this
monomer brings to the resulting polymers is not its Green Character alone. First, it can be
applied to standard polymerization processes already in place for making the petroleum based
relatives. This is a key aspect in bringing new bio based polymers to market at scale and cost
effectively. Second, it imparts unique performance characteristics that differentiate the
resulting polymers from their petroleum based relatives. This allows them to fill true
performance gaps in their polymer families. We will examine the performance characteristics of
PA 410 relative to the existing range of polyamide demonstrating that unique features (and
ultimately - economic value) beyond Green Character can be realized.
Advancements in Marine Biodegradable Bioplastics
The erosion of our coastlines and estuaries is a problem that is getting some help from an
unlikely source – bioplastics. Restoration is achievable through sound planning, use of advanced
environmental practices, and understanding the importance of natural habitat in both the
water and surrounding land. However, advances in bioscience can help achieve these goals.
We will discuss how the properties of bioplastics make the material a suitable solution for
manufacturing marine-related products. Certain bioplastics have the unique ability to
biodegrade in marine and freshwater environments, in accordance with ASTM D7081 for
marine-biodegradable non-floating plastics. This standard specification, along with the standard
method ASTM 6691 for determining aerobic biodegradation of plastic materials in the marine
environment, was developed at the U.S. Army Natick Soldier Research, Development and
Engineering Center (NSRDEC) in Natick, Massachusetts, with support from the U.S. Navy and
the Waste Reduction Afloats Protects the Sea (WRAPS) Program.
This session will explain what is required to meet the standards for the biodegradation of
water-resistant yet marine-biodegradable bioplastics. The presentation will also discuss how
bioplastics safely biodegrade in marine environments, highlighting the types of commercial
product applications that are ideal for these new materials.
Marine Biodegradation of PLA, PHA, and Bioadditive Polyethylene Based on ASTM D7081
PHA compostable plastic materials demonstrated marine biodegradation per ASTM D-7081
standard. Two PHA-based films and cellulose paper biodegraded over 30% after 180 days while
at 30°C and under conditions of the ASTM D-6691 test method. Biodegradation was measured
by CO 2 evolution from samples in glass jars. PLA based plastic cup, PLA-based snack bag, and
polyethylene film negative control did not meet 30% biodegradation in 180 days. Bio-additive
polyethylene based trash bag and ziplock bags did not meet the marine biodegradation
standards in ASTM D-7081.
Improving the Mechanical Properties of Polyethylene and Polypropylene Recycled Streams using Polyolefin Elastomers and Functionalized Polyolefins
An important attribute for many plastics is the ability to be recycled. By melting and
reprocessing thermoplastics for re-use, the carbon footprint can typically be reduced compared
to the use of virgin materials. The benefits of incorporating recycle content into new and
existing applications, however, must be tempered by the reality that recycled plastics may not
have the same performance as virgin materials due to either 1) degradation by
weathering/aging, 2) contamination, or 3) thermo-mechanical degradation from re-processing.
To minimize the intrinsic effects of the recycling process and allow usage of recycled plastics
such as polyethylene (PE), polypropylene (PP), or streams with mixed content, it is important to
understand the benefits of utilizing impact modifiers and compatibilizers.
Reclamation of Polyester Waste: Cost Effective Improvement
in IV and Melt Viscosity
Reclamation of polyester waste in the fiber industry is well known and a seemingly well
developed process. It offers numerous benefits to fiber producers. These benefits include but
are not limited to the following: conservation of oil, reduction of greenhouse gas emissions,
saving landfill space and energy conservation. Unfortunately, in spite of these benefits, total
recycling of polyester does not exceed 25%. The main reason for low recycling rates is the
hydrolytic instability of polyester resin leading to a severe drop in the polymer’s viscosity. This
deterioration in polyester viscosity is amplified due to high temperatures and shear rates
involved in fiber processing. Existing methods to preserve IV and melt viscosity of polyester
resin include solid state polymerization (SSP), and gaining popularity in the last 25 years, Erema
recycling technology. Both of these approaches include significant capital investment in
equipment and both are rather energy consuming. We are offering an alternative approach to
maintain or even increase IV of polyester resins during recycling or direct processing of fibers
and yarns. Developed by Goulston Technologies, internal polymer additives work like linear
chain extenders and offer a cost effective improvement in IV and melt viscosity of polyester
resins. These additives are based on bi-functional reactive chemicals and are available in a form
of highly concentrated master batches that can be dosed directly into the waste stream. These
additives are capable of significant increase in IV and melt viscosity without cross linking and
corresponding gel formation, and clogging of the spinning packs. This additive technology offers
polyester processors a safe and cost effective alternative to capital intensive investments.
Paper-Plastic Biocomposites
ECO Research Institute (ERI) has developed a dry grinding method that pulverizes waste paper
to the micron size range and that powdered recyclate is then used as filler in thermoplastics.
Using this technology reduces carbon-dioxide emissions by as much as 60-80 percent compared
to using traditional thermoplastics while also enhancing mechanical properties.
ERI has seen its business growth very rapidly in Japan as the technology does not suffer from
any of the processing and performance limitations of other bio-plastics. The ERI materials are
now widely used in automotive, electric, food, housing, transportation and toy industries. ERI is
now expanding capacity through its US subsidiary in cooperation with Michigan Molecular
Institute, which will bring compounding capabilities to the U.S. under the name Eco Bio Plastics
Midland, Inc.
Paper has been one of the oldest products for the history of human being and it has been
produced on a huge scale basis all over the world. The basic application relies on the
technology of utilizing long cellulose fiber for processing. Paper is also known for high level of
recycling, mostly by producing recycled paper.
We have investigated the possibility of:
1. Finding new technology of paper other than the application of long cellulose fiber
2. Recycling paper other than producing recycled paper
3. Creating more environmentally friendly material by utilizing non-hydrocarbon based
paper
We have succeeded in developing new technology of pulverizing paper into micro powders as
minute as 30μm and compounding it with conventional plastics in the form of pellets for the
purpose of mass production. Pellets can contain up to 70% paper. This paper-reinforced plastic
composite can reduce CO2 emission dramatically since the main material is paper. Currently the
technology is commercially available in polypropylene for injection molding or thermosetting
products but other formulation with different based materials such as PE, PS, PLA and PHA for
different processing is on-going.
Development of a Recycling Database for Material Re-Use and
Landfill Tracking
International Automotive Components Group has developed an internal database to track
manufacturing scrap, material re-use, landfill and team action items among other things. The
database enabled IAC to measure the amount of landfill resulting from various processes and
then target specific areas. Regrind use was optimized to assure quality and best possible
application. Via this database, landfill numbers, regrind use, and projects were graphically
displayed to show the progress in each area. The database proved the adage ‘What is measured
is managed and what is managed is improved” Examples of the capabilities of the database will
be presented. The ability to track and measure also proved this database to be a very useful
tool for management reporting. Based on these efforts, IAC was able to reduce their landfill
from manufacturing by 36 million pounds in 2010.
Research and Application of Post Consumer Recycled Plastic in Electronic Products
Over the years there has been an on again - off again relationship between consumer electronic
products and post consumer recycled materials. The use of these materials is ultimately desired
for the environmental benefit to our world, but also for the potential financial benefit of
reclaiming a high value waste stream. To most outside the plastics or recycling industries,
recycling plastics seems like a simple and obvious thing to do. The reality of it however is much
more complicated. Ever-changing variables such as supply and demand, shifting waste streams,
environmental regulations, and the price of oil, keep the sand shifting under the feet of those
trying to succeed in this field. We will try to bring to light many of the issues and present some
achievements along the way. With the learning of the past twenty years and new technological
advancements it seems that this industry is beginning to turn a corner and achieve a stable,
quality supply of post consumer recycled (PCR) materials. Coupling this improved supply with a
more stable and increasing demand for Post consumer materials may make it possible for
recycled engineering plastics to soon make their way into more consumer electronic products.
Methods for Protecting Polymer Recycle Chain and Intellectual Property of Advanced Polymers
The financial burden that accompanies the recycling of polymers when required by local laws
and regulations will continue to grow in the next decade as more counterfeit products enter
the marketplace. Manufacturers will begin spending more time and money attempting to
recycle materials they did not produce than on actual production. In the same vein, companies
that continue to innovate and produce specialty polymers are susceptible to counterfeiting.
Counterfeiting leads to financial liability from product failures and losses in both customer
confidence and revenue.
When forced to recycle another manufacturer’s polymers, a company exposes themselves to
the possibility of introducing inferior, harmful, and possibly dangerous polymers into their
production facility and eventually into the hands of consumers. This exposes polymer producers
and brand owners to liability if there are illnesses or product failures from recycling counterfeit
materials. If inferior product is not detected prior to the time of recycling, a large amount of
resources will be occupied separating good and bad polymers, increasing the likelihood that the
cost of goods produced from recycled materials will be priced out of the market.
Manufacturers and recyclers need tools that can be used to help them instantly identify their
product from counterfeit materials. This paper will present several options to protect the
polymer supply chain from cradle to grave to and back to cradle, methods to help reduce
liability from inferior raw materials entering the marketplace, and protect intellectual property
by ensuring advanced, specialized polymers are from legitimate sources.
Sustainability from Start to Finish: The Lifecycle Impacts of Plastic Packaging
Sustainability is now a business fact, yet many of
those asking for improvements to “sustainable
packaging” lack the fundamental understanding
needed to make the best possible business
decisions. Scientific information is needed from
production to end-of-life to determine what
makes a package more “sustainable”. The 3 Rs
(Reduce, Reuse, Recycle) are often the first steps
for many individuals and businesses on their
journey to becoming more sustainable, although
new “R’s” such as Renew and Recovery are
appearing. Using science-based criteria can help
improve the understanding of how plastic
packaging contributes to a sustainable society.
Plastic packaging can prevent spoilage and
damage to food and other products during
distribution and storage. Plastics are light weight
and frequently require less raw material and
energy than other materials used for packaging.
Plastics can be recycled and recovered at their
end-of-life. Significant progress has also been
made in the development of bio-plastics, but
there continues to be confusion as to what bioplastics
are and how to properly assess their
environmental impact. Sustainability
performance cannot be defined with a single
attribute but must consider a product’s entire life
cycle.
This abstract/presentation will begin with
examples demonstrating the sustainability
benefits of plastic packaging, then define what
bio-plastics are and why the diversity of bioplastics
and their varying properties make it
difficult to make simple, generic assessments as
to whether plastics made from traditional or
renewable feedstocks are “good” or “bad”, and
conclude with a discussion of end-of-life options
for packaging, including recycle-to-energy.
Marketing the Message of Sustainable Plastics Packaging
Recycled-content or bioresin packaging will require
more than just the right technology and materials for
sustained growth. Sustainable packaging expansion will
also require increasing the number of informed,
enthusiastic retailers and packaging users that are
interested in being “greener.” This paper examines one
way in which resin, packaging, and packaged-goods
producers are attracting attention to the recycled-content,
recyclability, or bio-basis of new plastics packaging.
Messages on the packaging itself are used to make green
claims and create branding, sometimes approaching (or
overstepping) the boundaries of “greenwashing.” This
paper considers the effectiveness of various messages,
and, referencing proposed 2010 U.S. Federal “Green
Guides,” considers the ways in which a clear, honest
sustainability claim can be communicated to both
informed and skeptical audiences.
Recent Advancements in Regrind Properties of Long-Glass Reinforced
Two separate studies were completed to look at recovery of long glass fiber (average glass
length = 10-15 mm) reinforced polypropylene. The LGF PP regrind in one case was molded at
various percentages with virgin material and the other study involved property evaluation of
100% LGF PP regrind. The basis of the study was to evaluate use of typical grinders (grind size of
5/16”) and extruders to simulate conditions commonly found in most plastics molding facilities.
Recommendations for addition of regrind to virgin materials are also presented based on
evaluation of the properties obtained.
Material Separation and Recycling of Mixed and Shredded Plastics from used Household Appliances
The separation and recycling technologies of shredded
plastic mixture from waste household appliances have
been developed. The separation technology was based on
the characteristics of specific gravity, electrostatic charge
and X-ray transparent of the plastics. The separated
plastics were recycled by the technologies of contaminant
reduction and material reformation. Furthermore, the first
massive and high purity plastic recycling plant for
polypropylene (PP), polystyrene (PS) and acrylonitrilebutadiene-
styrene (ABS) in Japan has launched in 2010.
This plant is able to separate the shredded plastic mixture
up to 10,000 ton annually, and the recycled PP, PS and
ABS have high purity more than 99%.
Shredder Technologies for Improving Resin Reclamation Processes and Economics
Reclaim extrusion lines rely on high quality
reclaimed resin, which must come from balanced, high
performance, and properly designed reclaim lines. These
systems must be properly configured for the tasks at hand, and
the implementation must allow for the complete business plan.
Material volume is not the only data point upon
which such a system must be judged on. If simple volume
were the judgment, reclaimers, recyclers, and reprocessors
would simply buy the largest and cheapest solutions available.
Nothing could be further from the truth. Inadequate processing
capabilities of the size reduction equipment can cause many
problems, including the following:
• Poor quality regrind
• High levels of material degradation
• Possible material contamination
• Poor performance due to machine maintenance and
overall condition
• Poor material ingestion and processing
• Improper operation due to machine design
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