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Recycling Per Country in 2016

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Recycling Per Country in 2016 Sustainable use of PCR-PET in a circular economy scenario Alessandro Falzoni SACMI Packaging Lab Director Company profile 2 SACMI Imola SACMI Imola is the parent company of the SACMI Group. An Italian cooperative that leads the world in the design, production and marketing of industrial technology and manufacturing systems for the ceramic and packaging industries. On the market for almost 100 years, SACMI is now a major Italian enterprise in terms of size, sales, territorial coverage and services offered. A network of over 80 companies with sales 4.305. employees, and assistance services, including SACMI world region employees of whom 1.343 30 production facilities in Italy, Germany, Egypt, Iran, USA, Mexico, Brazil, India, outside Italy Indonesia, China Germany 326 Russia 33 Europe 119 China 391 N.America 143 Italy 2.962 India Far East 115 88 S.America 44 Africa 16 Middle East 68 Revenues from sales and services 1434 1 394 1 354 1 227 1 196 16% 14.6 13% 15% 12 % % in millions of Euro Italy 2013 2014 2015 2016 2017 Ebitda 170 165 155 147 156 in millions of Euro 2013 2014 2015 2016 2017 SACMI Businesses Ceramics Packaging Food Service & Automation . Tiles . Closures . Processing & . Shipping & Logistics . Sanitaryware . Containers molding . Administrative & IT . Tableware . PET preforms . Primary Service . Heavy Clay . Beverage packaging . Quality control . Special . Secondary . Factory data Pressing packaging processing & control . Technical . Wrapping . Inspection Systems Ceramics equipment . Electrical engineering EXTENSIVE COMPETENCE INCORPORATED IN THE SAME STRUCTURE NECK FINISH CHOICE CAP DESIGN Developed a new neck finish TOP LOAD Simulation vs. Test Case Study of PREFORM Sacmi-LAB + R&D center DESIGN STRETCH BLOW-MOLDING Simulation vs. Test CLOSURE/FINISH COUPLING CONTAINER DESIGN by x-ray photos new bottle design and development to meet customer requirements INJECTION PREFORM SYSTEM IPS 9 THE AGE OF IPS SACMI INJECTION PREFORM SYSTEMS SHARED DNA - PROJECT DRIVERS 1.PERFORMANCE Fast cycle time Low energy consumption (KERS, self- adaptive setting) Fast format changeover & machine start- up 2.FLEXIBILITY Modularity Mould interchangeability with most common moulds and HH present on the market 3.EASY TO USE HMI intuitive and user friendly Automatic process set-up for new preform design Integrated control of auxiliaries 4.RELIABILITY High system availability IPS Injection Preform Systems IPS 220 IPS 400 IPS 300 EASY, FAST & EASY & NEWCOMER VERSATILE ( POWERFULL change-over under 50’) Integrated Quality Control System BOTTLE TO BOTTLE SACMI IMOLA Jan, 22th 2019 Annual consumption of plastic bottles 14 Plastic post-consumer - Rates of recycling per country in 2016 Countries with landfill restriction implemented Source: PlasticsEurope Source: 15 In ten years, plastic packaging recycling has increased by almost 75% Source: PlasticsEurope Source: 16 Benefits of Recycling • Recycling saves natural resources When we recycle, used materials are converted into new products, reducing the need to consume natural resources • Recycling helps protect the environment Recycling reduces the need for extracting (mining, quarrying and logging), refining and processing raw materials. All of these create substantial air and water pollution. • Recycling contributes to creation of jobs Recycling opens up job opportunities. Recycling means many recycling plants will be set up, thus, leading to a long chain of collection and delivery. All these activities are performed by humans, so this will trigger an explosion of opportunities. 17 European Parliament takes historic stand against single-use plastic October 24, 2018 • A EU-wide ban of single-use plastic cotton buds, straws, plates and cutlery (with exemptions until 2023), beverage stirrers, balloon sticks, oxo-degradable plastics and expanded polystyrene food containers and cups • An obligation for EU countries to adopt measures to achieve a 25% reduction of the consumption of food containers and cups for beverages • An obligation for EU countries to reduce post-consumption waste from tobacco product filters containing plastic by 50 % by 2025 and 80 % by 2030. • Extended Producer Responsibility (EPR) schemes that include the cost of clean up and awareness raising measures. • Harmonized standards and an Extended Producer Responsibility (EPR) scheme for fishing gear, as well as a 50% collection target and a 15% recycling target for fishing gear by 2025. • An obligation to separately collect 90% of beverage containers and ensure they are produced from 35% recycled content by 2025. • An obligation to prevent the use of hazardous chemicals in the composition of sanitary items. • An obligation to label products to inform consumers about the presence of chemicals of concern in certain single-use plastic products. 18 Waste hierarchy Mechanical Chemical Better Option Reduction Reutilisation Recycling Energy recovery Product Disposal Waste Worse Option 19 Production cycle of polymers Raw material Processes extraction Crude & USE Landfill Oil conversion & Melting Processing X Polymerization FUELS Reuse (tertiary) recycling Chemical Chemical recycling Mechanical Mechanical (secondary) Energy recovery (quaternary) 20 Recycling Mechanical Recycling • Conventional • Super-Clean processing involves the removal of contaminants with maintenance and raising of intrinsic viscosity (IV) to bottle grade (0.75-0.82 dl g-1). 21 Challenge test • Recyclers must be able to demonstrate that contaminant levels in the reformed plastic have been reduced to sufficiently low levels to ensure that the resulting packaging is of a purity suitable for its intended use. • During the challenge tests, plastic flakes are spiked with selected chemicals, so called surrogates, representing all groups of common contaminants and then submitted to all steps of the recycling process.* • For FDA – 2006 - chemical contaminants shall not exceed migration levels of 0.5 ppb, leading to an estimated daily intake of 1.5 µg/person/day.* • For EFSA (European Food Safety Authority) – 2011- PET recycling processes on a human exposure threshold of 0.0025 µg/kg bodyweight/day for any unknown contaminant possibly present.* Volatile Polar Volatile Non-Polar Non-Volatile Polar Non-Volatile Non- Chloroform Toluene Benzophenone Polar Tetracosane Chlorobenzene Heavy Metal Methyl salicylate Lindane 1,1,1- Copper(II) 2- Trichloroethane ethylhexanoate Methyl stearate Diethyl ketone Phenylcyclohexane 1-Phenyldecane *Source: Journal of Cleaner Production 2,4,6-Trichloroanisole 22 Mechanical PC Recycling in flakes Conventional recycling – Super clean – for food non-food contact contact Intensive washing Feeding with hot caustic soda Bale solution (NaOH) Peeling-effect Rotary tubular kiln Bale dissolver Heat and vacuum Up to 200°C for 5h treatment Volatile contaminants are removed Manual (large items) Dry Sorting The salt formed during this Rewashing process is sieved and Metal Separation Automatic rewashed • Optical sensors (separation of Hot Prewashing transparent, colored, opaque) Drying • Near infrared -NIR- (separation of all types of plastics, except black object) Grinding • X-ray (separation of PET and PVC) Sieving and Sorting • Laser sensors Sink/Float separation Dedusting Drying The final material has to fulfil the requirements of the plastics Mechanical Flakes Storage regulation (EU) Nr. 10/2011 Centrifuge 23 Effects of contaminants in recycled PET Possible contaminants present in recycled PET: • PVC; • Colored plastics including black plastics; • Metals; • Plastic film, bags; • Other non-plastics materials such as paper, glass and silicone; • Other plastics heavier than water (PS, ABS); • Fines, dirt, loose labels and rubber. Quality issues related to recycled PET • Yellowing (impact on b value); • Drop in intrinsic viscosity (IV); • Haziness (due to induced crystallinity); • Black specks. 24 Specifications PET flakes* rPET* PROPERTY UNIT VALUE RANGE VALUE RANGE Intrinsic viscosity (IV) dl/g 0,74-0,83 Average 0,80 +/- 0,03 Average Bulk density Kg/m3 300-500 Min. - Max 850 Average Size mm 5-10 Min. - Max 2-3 Average Moisture % 0,3 Max 0,2 Max Acetaldehyde ppm 1,5 Max 1,5 Max 1- 5 mm fraction % 7 Max 0.6 mm fraction % 0,3 Max *Food contact *Low dust content Crystallinity % 38 Min. PVC polymer ppm 5 Max Polyolefin ppm 50 Max Paper ppm 15 Max Glue ppm 10 Max Metal ppm 5 Max 25 Recycled PET products Amorphous Food Up to 5% - PET contact Flakes Crystalline Bottle grade – PET and food Up to 50% Flakes contact Crystalline Bottle grade and food Up to 100% Pellet contact 26 How to mix the Amorphous - PET Flakes up to 5% STANDARD DRYING HOPPER WITH A THREE- WAY VALVE FLAKES PET 27 How to mix the Crystalline –PET Flakes up to 25% DOSING STATIONS FLAKES PET WEIGHING HOPPER MIXING CHAMBER A METAL DETECTOR CAN BE APPLIED ALONG THE PIPEWORKS – before the hopper TO THE DRYING HOPPER In industrial production, this feeding system is used up to 50% combined with a standard machine IPS400 28 How to mix the Crystalline –PET Flakes up to 50% and more Two dedicated hoppers up to 50% of flakes are recommended. A hopper for virgin PET and a hopper designed specifically for flakes. Over 50%, the two hoppers are strictly required, due to: • Bridging risk; POST- • Preferential layers; CONDENSATOR • Different drying conditions. DE-DUSTING UNIT AND POST- CONDENSATOR ARE USUALLY RECOMMENDED DE-DUSTING SYSTEM 29 How recovery and cycle time change with flakes VIRGIN PET FLAKES 30% FLAKES 50% 3 0 Recycling Chemical Recycling • Depolymerization and regeneration of monomers and oligomers
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