Post-consumer recyclates for automotive applications

TechnoCompound GmbH, Bad Sobernheim, and RE Plano GmbH, Lünen, a subsidiary of REMONDIS Recycling, have agreed to intensify their cooperation in the use of post-consumer recyclates (PCR) for automotive applications. This is being done against the backdrop of the numerous EU regulations that are currently being discussed and have already been passed regarding the sustainability of companies and products, including the End-of-Life Vehicles Directive.

The use of recyclates from the lightweight packaging fraction of household waste sorting for use in technical products presents many challenges. Both companies have made significant developments and investments in this area in recent years. Dirk Breitbach, Managing Director of TechnoCompound, comments: “Building on our 35 years of experience in the use of recyclates in plastic compounds, the cooperation with RE Plano is an important step in the up-cycling of PCR from the lightweight packaging fraction for technical applications, such as vehicle interiors. This application has very high requirements in terms of emissions and odours, as well as the mechanical properties of our products.”

At its latest sorting plant in Bochum/Germany, RE Plano uses an AI-supported sorting system that recognises individual packaging and can be freely programmed in terms of sorting criteria. This enables the company to achieve the highest purity levels in the fractions, which are suitable for later use in, for example, cosmetics packaging and vehicle interiors. Managing Director Ralf Mandelatz: “This will enable us to meet the volume requirements of the automotive market, and we are delighted to have TechnoCompound, an experienced market leader in technical applications, on our side.” Dr Nabila Rabanizada, Head of Research & Development at REMONDIS Recycling, adds: “The suitability of our recyclates, including for high-quality, contact-sensitive applications, is also ensured by the further multi-stage processing of the sorting fractions at our plant in Lünen. This enables us to meet the specifications for the individual components.”

Through compounding, additivation and further material processing, TechnoCompound uses these raw materials to produce plastic grades that pass the emission chamber tests, including odour and emissions, specified by vehicle manufacturers (OEMs). Regardless of the exact form of the future ELV directive, OEMs and Tier 1 and Tier 2 suppliers are pursuing their own sustainability strategies that include the use of PCR. Dr Gerald Aengenheyster, Head of Development & Application Technology at TechnoCompound, comments: "We can offer material solutions where PCR and post-industrial recycled content (PIR) are balanced according to the application and specification."

While the recovery of PCR from end-of-life vehicle recycling is still in its infancy, developments for the use of the PCR light packaging fraction are now well advanced and available for series application. TechnoCompound's PCR-based plastics are already being used in a number of automotive applications. Examples include instrument panel carrier made from TechnoGreen PP LGF long glass fibre reinforced polypropylene grades, which are in production for two vehicles. By working together, TechnoCompound and REMONDIS Recycling are helping their automotive customers to meet legal requirements and further achieve their sustainability goals within the circular economy.

TechnoCompound GmbH (www.technocompound.com) in Bad Sobernheim, Germany, which is part of the Polymer-Group (www.polymer-gruppe.de) is a leading supplier of tailored polymer compounds in Europe and has a staff 90. It has state-of-the-art production facilities, and compounds, finishes and modifies polymers with a production capacity of 60,000 metric tons per year for customer-specific applications. The functionally modified polymer range extends from commodities via technical compounds to thermoplastic elastomers.

These polymers are primarily used by the automotive industry and its suppliers. However, applications in logistics, packaging and construction are also served. Its lean organization and modern facilities optimized for efficiency mean TechnoCompound GmbH is able to offer its products at competitive prices. Its full-service offering includes on-site technical application support and the development of compounds individually tailored to a specific application.

The Polymer-Group, with its registered office in Bad Sobernheim, emerged from Polymer-Chemie GmbH, an independent family business founded in 1973 to compound, finish and modify plastics. Combining flexibility and performance, it is increasingly supporting its global customers with innovative and customized products of the highest quality. Today, the Polymer-Group comprises the compounders Polymer-Chemie, Polymer-Chemie Rus, Sun Alloys Europe, TechnoCompound, PolyMIM and SoBiCo and has over 500 staff.