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For Realization of a Circular Economy

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For Realization of a Circular Economy For Realization of a Circular Economy Under Toray Group Sustainability Vision, “a world where resources are sustainably managed” is one of perspectives of the world that we aim to realize by 2050. Society has so far faced various issues such as resource depletion, marine pollution from significant garbage inflow, and CO2 emis- sions. To solve these issues, Toray has positioned measures to realize a circular economy that effectively uses resources, as a key theme in “Project AP-G 2022.” Toray Industries, Inc. Integrated Annual Report 2020 68 Realizing a Circular Economy through Various Technologies and Products Toray is contributing to the realization of “a world where resources are sustainably managed”—the so-called circular economy—through various technologies in such areas as recycling of plastics, utilization of biomass in raw materials, use of renewable and hydrogen energy, and reuse of water. For example, Toray is engaging in material recycling*1 and recycling within our operating processes, which reuse plastic products such as fibers and textiles, resins, and films. In addition, we have already produced nylon fiber products through chemical recycling*2 that turns unrecyclable plastics into basic chemicals such as monomer and gas. Furthermore, Toray is promoting the development of products made using plant-derived raw materials rather than petroleum, and membrane-integrated biotechnology that effectively produces these raw materials. Moreover, Toray technologies are being used in areas including materials for wind turbine blades that generate energy used in manu- facturing processes, materials for equipment that produces hydrogen used to generate renewable energy, and water treatment membranes for recycling wastewater. *1 Material recycling: a recycling process that uses heat to convert used plastic bottles and remnants produced during manufacturing processes into yarn, staple fiber, and other materials. *2 Chemical recycling: a recycling process that breaks down through depolymerization used products and remnants produced during manufacturing processes into monomers that are manufactured back into chips and then recycled into yarn, staple fiber and other materials. Contribute to initiatives including biomass plastics, recycling, promoting of renewable energy and the use of hydrogen, and water reuse Raw material Production Use Recycling within Fossil operating processes, etc. resources Toray materials Membrane- (fibers & textiles, integrated Use of plant-derived raw materials resins, films) biotechnology (bio-PET, nylon raw material, etc.) reuse Raw used Biomass pellets material plastics PET (fibers & textiles, films), ABS resins Material recycling Nylon fiber products Chemical recycling Emission gas (CO2) ras tehnlgies related t energ Waste Thermal recycling and water that supports a circular economy Gas separation membrane Electric Hydrogen power from Water from renewable treatment oy enoloie renewable energy products energy Toray Industries, Inc. Integrated Annual Report 2020 69 Using Biomass Toray has developed processing technology that realizes energy and cost reductions by applying water treatment mem- branes to the biomass saccharification process, which produces cellulosic sugar from non-edible biomass, and is oper- ating a demonstration plant on a trial basis. Toray is pursuing the creation of supply chains that make practical use of this process to manufacture materials and chemicals from non-edible biomass. At the same time, Toray is mass producing partial bio-PET fiber, a biomass-derived fiber made from plant-based ethylene glycol that is used to make such products as Ultrasuede® PX, a nonwoven material created using ultra-fine fibers in an “island in the sea” configuration. At present, Toray has completed prototype production of 100% bio-PET fiber at its demonstration plant, positioning it as a top-level environmentally friendly material mainly for sportswear and automotive interior applications, and Toray aims for mass production as early as possible in the 2020s. ato T l t The reuse of production process wastes and used plastic bottles as raw materials Conversion/ Polymerization/ is expected to reduce the use of fossil resources and reduce wastes Saccharification Refinement Polymer processes Collection Sorting Shredding Cleaning Cellulosic Bio- Fibers & Films Resins sugar chemicals Textiles Melting and Pellets Flakes Biomass extrusion (cellulose) Inspection Spinning Apparel Membrane-integrated Partial 100% saccharification process Bio-PET fiber Bio-PET fiber ollto a lato T l t A processing technology that realizes cost (already in mass production) reduction through energy-saving and recy- cling by applying water treatment membranes Products and collection system originally designed for collection and recycling after use for the biomass saccharification process. MF UF NF RO Biomass mem- mem- mem- mem- Cellulosic brane brane brane brane sugar Bio- Toray chemicals Caprolactam Polymerization Synthesis Refinement • Completed prototype pro- duction at the demonstra- tion plant Crude Nylon 6 • Positioning it as a top-level caprolactam environmentally friendly ® “Ultrasuede PX,”a material, started proto- Sponning/ nonwoven material type evaluation mainly for Weaving created using ultra- sportswear and automo- Re-use of Recovery of liquids Fabrics and Installed demonstration plant for cellulosic fine fibers made tive interior applications materials after and waste from products made sugar production in Thailand, started proto- with plantbased raw • Aim for mass production depolymerization production of Nylon 6 with Nylon 6 type evaluation by customers. materials in the 2020s Pre-processing: Sale Collection and Metals and other foreign Users substances are removed pre-processing Toray Industries, Inc. Integrated Annual Report 2020 70 Promoting Recycling Toray is expanding its ECOUSE™ regeneration type recycling material and CYCLEAD™ collection circulation type recycling system into a wide array of business fields including fibers and textiles, resins, and films. As for regenera- tion type recycling, in fiscal 2019, Toray kicked into full gear advanced initiatives to recycle collected plastic bottles to be used as raw materials for textiles and established the new textile business brand &+™ (And plus) with the aim of realizing a sustainable society. As for collection circulation type recycling, Toray has developed its proprietary material recycling system that collects and recycles used fiber and plastic, and is leveraging this system to pursue initiatives in this field. ato T l t The reuse of production process wastes and used plastic bottles as raw materials Conversion/ Polymerization/ is expected to reduce the use of fossil resources and reduce wastes Saccharification Refinement Polymer processes Collection Sorting Shredding Cleaning Cellulosic Bio- Fibers & Films Resins sugar chemicals Textiles Melting and Pellets Flakes Biomass extrusion (cellulose) Inspection Spinning Apparel Partial 100% Bio-PET fiber Bio-PET fiber (already in mass production) ollto a lato T l t Products and collection system originally designed for collection and recycling after use MF UF NF RO Biomass mem- mem- mem- mem- Cellulosic brane brane brane brane sugar Bio- Toray chemicals Caprolactam Polymerization Synthesis Refinement Crude caprolactam Nylon 6 Sponning/ Weaving Re-use of Recovery of liquids Fabrics and materials after and waste from products made depolymerization production of Nylon 6 with Nylon 6 Pre-processing: Sale Collection and Metals and other foreign Users substances are removed pre-processing Toray Industries, Inc. Integrated Annual Report 2020 71 Fibers & Textiles The New &+™ Fiber Brand Made from Recycled Plastic Bottles Previously, plastic bottle derived-fibers were limited in variety due to contaminants mixed into raw materials, which made it difficult to produce special cross-sections and fine fibers, as well as issues posed by fiber whiteness being impaired by yellowing from plastic bottle degradation. In response, Toray together with Kyoei Industry Co., Ltd. devel- oped contaminant filtering technology and advanced plastic bottle cleaning techniques to stabilize the supply of raw materials that are impurity-free. Combining these technologies with Toray’s fiber production technology, it is possible to achieve diverse fabric applications with a degree of whiteness equivalent to fibers materials made directly from petro- leum source. Moreover, Toray has commercialized its highly reliable polyester fiber under the &+™ brand by incorpo- rating its proprietary traceability technology that can detect special additives premised in with plastic bottle-based raw materials. Full-scale sales of the &+™ products started in January 2020, and Toray targets sales of over ¥50 billion in 2025 by expanding the scope of sales by leveraging various supply chains (extending from yarn and staple fiber through to textiles and garments) and global production bases. CLEAN RECYCLING TRACEABILITY AUTHENTICITY Promoting Recycling with UNIQLO Together with UNIQLO CO., LTD., Toray is promoting new initiatives for sustainable products, with Toray supplying &+™ fibers made from recycled plastic bottles for UNIQLO’s quick-drying wear DRY-EX brand polo shirts starting in 2020. In addition, UNIQLO stores are collecting used down items from customers to recycle the feathers. Conventionally, the stuffing in duvets and other objects incorporating down is manually removed. Such processes are arduous with Ultra Light Down items because of their
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