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 by: • Hydrolysis • Methanolysis • Glycolysis

31 32 A New Chemical Recycling Approach

A chemical recycling process based on hydrolysis. Requires very little added energy for heat and operates at ambient pressure.

PET flakes is dissolved in an ionic liquid with catalyst containing magnetic nanoparticles of iron oxide. The mixed fluid is heated to a relatively low temperature (< 200 °C) at atmospheric pressure. The colorants and other contaminants are magnetically separated.

33 A New Chemical Recycling Approach

DEMETO (DE-polymerization by Microwave Technology) is a European Project financed by the European Community into the framework of the Horizon 2020. The partners of the consortium are working to bring to reality a revolutionary new way to chemically recycle PET, invented by gr3n.

CARBIOS has developed an enzymatic bio- recycling process for plastics that breaks polymers down to the basic components (monomers) originally used to create them.

34 Thank you

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