Circular Economy in the Rubber and Plastics Industry
The plastics and rubber industry's biggest area of activity is the Circular Economy.
No other task has occupied the industry as much in recent years as the development of a functioning Circular Economy for polymer materials. The vision: New material types with at least a proportion of PCR raw materials – with guaranteed quality on a par with primary products, easy and safe to use for every processor. Circular Economy starts at K.
Circular Economy: Definition and Basic Principles
What is the Circular Economy?
The Circular Economy is a sustainable economic system that aims to keep materials and products in circulation for as long as possible. The aim is to minimize waste and use resources efficiently.
Basic principles and functioning of the Circular Economy
The Circular Economy is based on the principle of reduce, reuse, recycle. For the plastics and rubber industry, this means
Reduce = reducing material consumption and waste production: in the plastics industry, this means producing less new plastic and using recycled materials instead.
Reuse = extending the life of products through repair and reuse: plastic products can be designed in such a way that they can be repaired or repurposed more easily through innovative design approaches.
Recycling = Returning materials to the production process: The development of efficient recycling processes for plastics and rubber plays a central role here in order to be able to reuse the materials after their first phase of use.
Products are designed to be durable and easy to repair or recycle. Materials are used efficiently and waste is minimized.
CO2 savings of up to
are possible through the recycling of plastics compared to the production of new plastics.
Source: SKZ
Why is the Circular Economy so important?
The Circular Economy is particularly important for the plastics and rubber industry to combat increasing resource consumption and environmental pollution. By implementing circular processes, the industry has the potential to develop sustainable products that are both ecologically and economically beneficial. Through circular processes, companies can reduce their environmental footprint while increasing efficiency and profitability. Efficient recycling processes and the reuse of plastics and rubber make a significant contribution to conserving natural resources and reducing waste.
Circular Economy starts at K.
Stories & Insights on the Topic of Circular Economy
The EU Circular Economy Action Plan is a comprehensive strategy of the European Union to promote the Circular Economy in Europe. The action plan comprises a series of measures and initiatives aimed at keeping products and materials in the use cycle for longer and avoiding waste.
Source: European Parliament Research Service
Main objectives and measures of the EU Circular Economy Action Plan
Product design and production: Promoting design approaches that make products more durable, repairable and recyclable.
Consumer empowerment: Supporting consumers to make informed choices and promoting sustainable consumption.
Waste management: Improving the collection and recycling of waste to recover valuable materials and minimize landfilling.
Promoting markets for secondary raw materials: Creating markets for recycled materials and promoting the use of secondary raw materials in production.
Sectoral measures: Specific measures for key industries such as the plastics, construction, textiles and electronics industries.
Significance for the plastics and rubber industry
The EU Circular Economy Action Plan is particularly relevant for the plastics and rubber industry. It promotes the development and implementation of recycling technologies that increase the use of recycled materials and reduce dependence on virgin plastic. The industry is encouraged to use more sustainable materials and develop innovative solutions to reduce environmental impact. By adhering to the guidelines of the action plan, companies can not only improve their environmental footprint, but also remain competitive and open up new business opportunities.
Circular Economy Newsticker
News about reusable systems, recyclates, bioplastics, eco-design & more
Dow has introduced a suite of low-carbon material solutions designed to assist the footwear industry in producing more sustainable products without compromising performance. This expanded portfolio includes bio-circular materials, reversible cross-linking resins, post-consumer recycled resins, and polyolefin elastomers suitable for artificial leather applications.
They look familiar, but they've got something special: the new shopping baskets from Lidl and Kaufland are made from recycled plastic. This turns waste into a high-quality product that conserves resources and reduces CO₂ emissions. With this step, the Schwarz Group is setting an example for sustainable retail.
Mount to Coast, a leader in ultrarunning footwear, has partnered with BASF to introduce CircleCELL™, an innovative running shoe midsole. The midsole, made from BASF’s ecoflex® BMB, blends sustainability with high performance, offering enhanced durability and energy return. This collaboration marks a significant step toward eco-friendly advancements in sports footwear.
Disposable packaging still dominates many logistics processes – often at the expense of efficiency and sustainability. A new reusable transport box aims to close this gap by conserving resources, saving costs and being flexible in use. The solution was developed by Fraunhofer LBF.
Everyone is talking about recycling, and yet there are sectors where it is only used to a very limited extent - for example in the textile and clothing industry. Fristdas has managed to create a closed loop recycling system for its clothing. In this interview, Lena Bay Højland explains how this affects the product range and what Fristads' vision is for further development.
This collaboration aims to reduce harmful emissions and enhance circularity in the plastics industry by offering environmentally friendly alternatives for consumer goods, packaging, and medical devices.
Neste Corporation and Mitsubishi Corporation (MC) have announced a strategic collaboration to develop value chains for renewable chemicals and plastics. This initiative focuses on supporting Japanese brands across various industries, including food and beverage, apparel, and consumer electronics, to reduce greenhouse gas (GHG) emissions and reliance on fossil resources.
The circular economy presents an increasingly complex challenge for companies. Sustainability is no longer just a compliance issue but a crucial success factor. In this context, Interzero offers a solution: the Materialkonto (‘material account’). This provides companies with a digital twin of their resource and circular management.
Recycling Services LLC, a prominent plastic recycler in Oman and Saudi Arabia, has joined forces with POLYSTAR to bolster the circular economy in the GCC region. This partnership, initiated with the acquisition of POLYSTAR's Repro-Flex 120 machine, aims to transform plastic waste into reusable materials, fostering sustainability and economic diversification.
For Marius Hamelot, the 2024 Summer Olympics in France will provide a glimpse into his vision of turning trash into treasure. An architect and entrepreneur, the 29-year-old Hamelot has been working for several years to transform waste plastic collected in local Parisian neighborhoods into high-quality, durable products.
In an ambitious move towards sustainability, Covestro, Neste, and Borealis have joined forces to revolutionize the recycling of discarded tires into high-quality automotive parts. This collaboration marks a significant step in driving circularity within the plastics and automotive industries.
Biolive, a pioneering biotechnology company, has launched a new biopolymer production facility in Istanbul, Türkiye, capable of producing 9,600 tons annually. Using olive pits as raw material, this innovative process aims to replace fossil-based plastics, offering a sustainable solution for the plastics industry.
TotalEnergies Corbion and Sulapac have joined forces to advance sustainable practices in the cosmetics sector, emphasizing the integration of recycled and biodegradable materials into product packaging, fostering a more eco-responsible industry.
Aquaculture takes a sustainable leap forward with the unveiling of a groundbreaking workboat hull constructed from renewable plastic. Borealis and AKVA group will introduce this innovation in Mo i Rana, Norway, in Spring 2024, marking a significant milestone for circularity in marine technology.
The textile industry is in the midst of a green transformation, with sustainability and recycling taking centre stage. This change is being driven by a growing awareness of the environmental impact of textile production and consumption. Plastics, particularly synthetic fibres such as polyester and nylon, are ubiquitous in the industry due to their versatility and cost-effectiveness.
Borealis announces the signing of an agreement to acquire a 100 % stake in Integra Plastics AD, an advanced mechanical recycling player based in Bulgaria. The investment will strengthen Borealis’ advanced mechanical recycling portfolio.
The forthcoming EU packaging regulation is casting its shadow: minimum quotas for recyclates are putting the plastics industry under pressure. Cirplus presents a digital platform that not only makes the recyclate market transparent, but also enables real-time coordination between the players.
Repsol has formed a new alliance with Pontegadea, incorporating them as a partner with a 49% stake in a portfolio of renewable assets valued at €740 million. This partnership strengthens Repsol's strategy of bringing in investors to accelerate their renewable energy goals, which include reaching 6,000 MW of installed generation by 2025 and 20,000 MW by 2030.
Experts from Ascend, a leader in recycling post-consumer carpet, and ReDefyne highlight new opportunities for recycled nylon, PET and PP. Their proprietary process allows them to convert end-of-life carpet into feedstocks for materials used in various finished goods, including automobiles and household appliances.
Borealis has finalized the agreement to acquire Rialti S.p.A., an Italian polypropylene (PP) compounder for recyclates. With the acquisition, Borealis expands its portfolio of PP compounds based on mechanical recyclates by 50,000 tons per year and is committed to accelerating the transition to a circular economy in the spirit of EverMinds™.
The company Röchling SE & Co. KG offers its Play-Tec® PCR recycled plastic, a construction material for the sustainable design of long-lasting playgrounds. This has now been awarded the Blue Angel eco-label in the category "Environmentally friendly recycled plastics" (DE-ZU 30a).
We all know the image: urban rubbish bins overflowing with disposable packaging. The Corona pandemic has made this problem more visible. The start-up MealGood has made it its mission to counter the throwaway mentality by developing bio-based reusable containers for the catering industry.
BASF SE celebrates the 25th anniversary of ecoflex®, the world's first PBAT biopolymer. Innovative biopolymers based on ecoflex® have been helping to solve numerous challenges in the plastics market since it came on the market. ecoflex® has also created new recycling opportunities for plastics and enables organic recycling.
BASF has published a life cycle assessment study on the environmental impact of mozzarella packaging that examines different sustainable raw materials for food-grade plastics. Flexible multilayer packaging with recycled or renewable raw materials has a significantly lower environmental impact compared to packaging made from fossil raw materials.
Recycling on your own doorstep sounds almost too good to be true. But it is possible, as the Hansgrohe Group in Offenburg shows. The special highlight is that Hansgrohe, in partnership with ImpulsTec GmbH, has succeeded in recycling galvanized plastics. This means that decoated ABS plastics can be recycled directly in the company.
Around 13.5 million tonnes of waste tyres are generated worldwide every year. This number is steadily increasing with the growing production and use of vehicles. While a significant portion of these tyres is already recycled or reused, there are also challenges such as current regulations. Nevertheless, tyre recycling remains an essential component of a circular economy.
Using its patented process, UBQ takes everyday garbage, strips out any abrasive metals, glass or minerals, and converts it into thermoplastic resins that be molded or extruded into a vast range of durable products. Such garbage is everywhere, hence the company’s name of UBQ, which stands for ubiquitous. It’s a global problem and requires a global perspective.
WILDPLASTIC® has set itself the goal of ridding the world of “wild” plastic waste and offering innovative recycling solutions. The Germany-based company differentiates its products through the unique use of plastic that is recovered from the environment to be recycled and reused as granulate.
Leonhard Kurz will be presenting new sustainable recycling solutions for PET film at drupa 2024. In a video interview, Markus Hoffmann, Member of the Board at Leonhard Kurz, explains how the company takes back and reuses used PET film to promote the Circular Economy. The DM Maxliner 3D machine, which impresses with its efficiency and versatility, is also presented.
The National Composites Centre (NCC), in collaboration with Munich-based Cevotec, showcases a sustainable solution for aerospace manufacturing waste, aiming to reclaim up to 80% of dry fibre material. This proof-of-concept could revolutionize waste management practices by utilizing innovative Fibre Patch Placement technology.
The world of plastic recycling has witnessed an outstanding alliance between two important players in the recycling industry: GANESHA ECOPET Co., a division of the largest Indian PET recyclers – GANESHA Group –, and SOREMA, the division of Previero Srl specialized in the construction of plastic recycling plants.
The specific requirements and high purity of plastic waste from life science research laboratories make recycling it a particular challenge. Re:Lab AB is tackling this problem with a chemical recycling process based on low-temperature conversion, which is a special form of gasification.
In a significant advancement for sustainable materials management, CARBIOS has teamed up with De Smet Engineers & Contractors (DSEC), renowned for its Engineering, Procurement, and Construction services in the biotech and agro-processing sectors. This collaboration aims to launch the world's first PET biorecycling plant in Longlaville, France, set to be operational by 2025.
The textile industry is facing major changes in sustainability, led by BASF and Inditex through the launch of loopamid®, a new technology for textile-to-textile recycling. This initiative represents a significant step towards a Circular Economy by offering a sustainable solution for the reuse of polyamide 6 (PA6), also known as nylon 6, from textile waste.
In a study, Gert Weber, Uwe Bornscheuer and Alain Marty have identified standards for laboratory experiments with enzymes for PET recycling. It emphasizes difficulties in upscaling and highlights the promising enzyme LCC-ICCG, which converts 98% of PET in 24 hours, is economically more efficient and proposes new standards for laboratory research on PET recycling.
Coperion has opened its Recycling Innovation Center, providing a high-tech test facility for comprehensive testing of plastics recycling processes. The center complements Herbold Meckesheim's technical center and enables customers to simulate the entire recycling process and test technologies before making an investment.
Geoff Germon has not only recognized the problem of plastic waste in Fiji, but also wants to help the locals tackle this problem and build a sustainable business at the same time. His approach starts with a simple plastic pole.
Thanks to aluminum-plastic laminates, our favorite snacks stay as crisp as we love them. But what if the shiny insides of snack bags hold much greater potential – one that goes far beyond accompanying a movie night? Passive cooling technology could benefit from upcycling these chip bags, says a research team from the University of Bayreuth.
LabCycle, co-founded by a University of Bath graduate, opens the UK's first pilot plant for recycling plastic lab waste into new lab consumables and aims to scale the technology for healthcare and research labs. Their process turns plastic waste into high-grade pellets, reducing energy and water use and promoting recycling in a circular economy approach.
Almost 90 % of all plastic packaging today still consists of virgin material. If we want to change this, we have to focus on chemical recycling in addition to mechanical recycling. According to the WWF study "Verpackungswende jetzt", a system change could save more than 20 million tonnes of new plastic by 2040. SÜDPACK is therefore investing in innovative chemical recycling technology.
Wherever there is movement in manufacturing, the plastic plain bearings and energy guiding chains from igus can be used. Even in packaging machines, e-chains and plain bearings made of high-performance polymers ensure movement. The products are durable but at some point they also have to be disposed of. igus has set up its own recycling programme for this purpose.
"By utilising our technology, we can produce a pyrolysis oil from strongly mixed plastic waste that also contains polymers such as PVC, PET, ABS and many others. We process the plastic waste the way it arrives from a waste sorting plant or from partners in industry."
"Chemical recycling is complementary to mechanical recycling and therefore of high priority for OMV – it is an important cornerstone of our Strategy 2030. It helps us to meet the growing demand for recycled polyolefins. Back in 2009 we developed a laboratory scale process that has since been patented."
Was multilayer packaging the Achilles' heel of the recycling industry? Not anymore, according to Krones and their project partners BASF, Südpack, and Tomra. Together, they're unveiling a solution that accomplishes what was once deemed impossible. At the heart of this innovation is a new
adhesive that enables effective material separation during the recycling process.
Coca-Cola India has launched the first 100% recycled PET water bottle in India, manufactured by Srichakra Polyplast on a Starlinger PET bottle-to-bottle recycling line. The launch followed approval from the Food Safety Authority of India, and Coca-Cola plans to further expand this sustainable packaging solution.
Recycling service provider Interzero developed a patented process to enhance the reuse of HDPE plastics, allowing the creation of blow-molded products from 100% post-consumer lightweight packaging material. The process uses a chemical modifier to control the recycled material's viscosity, making it suitable for blow-molding and eliminating the need for re-sorting and additional primary plastic.
"Don't lose it, reuse it!" is not just the exclamation of a puppy from a well-known animated children's series when he creates new objects from supposed garbage. Rather, it shows how important the topic of ‘recycling’ has become in general.
Covestro has started up a new production line in Taiwan to to produce high performance TPU suited for Paint Protection Film (PPF) grades. The new TPU-based PPF solutions will be offered under the brand name Desmopan®UP.
At Covestro's Wind Technology Center, research is being conducted into making wind technology more efficient. To do this, a close look is taken at wind turbines – where are opportunities to use special materials that drive renewable energy? The big goal behind it: Climate neutrality and a circular economy.
Plastics contribute to climate protection. As fibre-reinforced plastics for wind turbines or films for solar cells, they already play an important role in power generation from renewable energies. But the conventional solutions are not equally suitable for every area of application. This is where a new type of material comes into play that was developed at Saarland University.
Researchers at the University of Cambridge have developed a system that can convert plastic waste and greenhouse gases into sustainable fuels and other valuable products – using energy from the sun alone. In the system, two waste streams are simultaneously converted into two chemical products.
New data from Plastics Europe reveals a concerning trend: European plastics manufacturing has faced a steep decline, with total production dropping by 8.3% in 2023. For the first time, mechanically recycled plastics have also seen a 7.8% reduction. These challenges jeopardize Europe’s leadership in sustainable plastics and its transition to a circular economy.
In Espoo, Finland, VTT (Technological Research Institute Finland) and LUT University, in cooperation with industrial partners, have opened a pilot plant that converts carbon dioxide into high-quality plastic raw materials in an innovative way.
One of the European Union's declared goals is sustainable development by 2030 - a development that does not stop at the medical technology industry. Gradical GmbH advises medical technology companies on the choice of materials for their applications.
In a year's time, it will be that time again: K 2025 will open its doors and bring the global plastics and rubber industry together in Düsseldorf. From October 8 to 15, 2025, K will once again be the place where innovations are presented, new trends are discussed, and contacts are forged. The industry is already looking ahead to what will be on the agenda in October 2025.
How will we build in the future? Sustainability, energy efficiency and comfort are key requirements that modern materials must fulfil. Conventional building materials such as glass are reaching their limits. This is where a new polymer-based material comes in, intelligently combining natural lighting and heat regulation to reduce energy consumption.
Driven by increasing consumer expectations and regulatory requirements, the need to measure the use of sustainable materials and their associated carbon footprints has become essential. Covestro and Alibaba Cloud have teamed up to develop solutions that enhance supply chain transparency, focusing on sustainable plastics and carbon accounting through advanced digital technologies.
Charlie Tan has his work cut out for him. The 30-something, London-born Brit/Malay last November became CEO of the newly reconstituted Global Impact Coalition (GIC). The GIC has the stated aim of transforming the global chemical industry to net-zero by 2050.
The plastics industry faces the challenge of harmonising efficiency and sustainability without compromising on performance. With a unique portfolio of products and services, ONI-Wärmetrafo supports plastics processing companies in becoming more energy-efficient and environmentally friendly, which is of immense importance, especially in times of rising energy prices.
The debate about fluoroplastics and their environmental impact is reaching new heights. While environmentalists are calling for a ban on PFAS (perfluorinated and polyfluorinated alkyl compounds), industry associations are warning of the far-reaching consequences for numerous areas of application. A look at the arguments and challenges.
KORE Insulation has introduced an environmentally friendly EPS insulation with a reduced carbon footprint to be used in a major housing development in Ballyclare, Northern Ireland. The decision to use KORE's Low Carbon EPS was made by the Braidwater Group. KORE Low Carbon is made from Neopor® BMB by BASF.
The current Packaging Directive has not been able to reduce the negative environmental impact of packaging. The European Parliament has therefore voted on new rules for packaging in the EU. At the end of November, the Parliament clearly adopted the proposal.
Polytives GmbH, a spin-off of the University of Jena in the field of plastics technology, was awarded second place in the Lothar Späth Award for its cooperation partnership with the university on 16.11.2023. The company, which emerged from Prof. Schacher's working group, develops innovative plastics solutions for energy optimisation in production.
The REFORM project aims to develop sustainable electronic components using bio-derived materials to reduce the reliance on scarce metals. It addresses the environmental impact of e-waste by creating recyclable and eco-friendly printed electronics, involving various European partners, including AIMPLAS, to develop innovative recycling methods.
The Circular Economy represents a significant paradigm shift for companies. It offers companies numerous opportunities to operate more sustainably and efficiently. Companies that adapt to this change at an early stage can not only increase their competitiveness, but also make a valuable contribution to conserving resources and protecting the environment.
Advantages of the Circular Economy for companies
Cost savings: By reusing materials and optimizing production processes, companies can reduce their raw material and disposal costs.
Promoting innovation: The need to make products more durable and recyclable leads to new opportunities for innovation in design and technology.
Competitive advantages: Companies that focus on sustainable practices can differentiate themselves from the competition and open up new markets.
Brand loyalty and reputation: Consumers increasingly value sustainability. Companies that commit to the circular economy can strengthen their brand and promote customer loyalty.
Forecasted growth in the market for recycled plastics
Source: Fortune Business Insights
Challenges and adjustments
Product design: Companies must design their products in such a way that they are easy to repair and recycle. This may require a change in previous design principles.
Supply chain management: Integrating circular principles into the supply chain can be complex and often requires new partnerships and collaborations.
Investment in technology: Ensuring effective recycling processes and material recovery often requires significant investment in new technologies and equipment.
Regulatory requirements: Companies must adapt to new legal requirements and standards that arise in the course of the Circular Economy.
Practical examples of the Circular Economy in the plastics and rubber industry
Recycling of production waste: Companies can collect waste generated during production and reintroduce it into the manufacturing process.
Use of recycled materials: The use of recycled plastic and rubber in new products reduces the need for new raw materials and reduces the environmental footprint.
Product take-back programs: Implementing programs that allow customers to return used products to be recycled or remanufactured.
of consumers are willing to pay more for products made from recycled materials.
Source: PwC
Circular Economy and Digitalization
In the implementation of the circular economy in the plastics and rubber industry, digitalization plays a central role.
Digital solutions enable ...
Efficient monitoring and optimization of raw material and product flows
Reduction of waste and conservation of resources
Better traceability and reuse of materials
Promotion of sustainable production cycles
By combining the circular economy with digitalization, companies in the plastics and rubber industry can achieve their sustainability goals and increase their competitiveness at the same time.
An innovative tool called CYCLOPS – Circularity Optimisation for Plastics has set itself the task of closing the gap between the need for information and the supply of recycled materials. By providing comprehensive data and assessments, it helps companies to make more sustainable decisions and organise their production processes in a more environmentally friendly way.
Vytal and PepsiCo are taking reusable tableware to a new level in their cooperation. With individual IDs for each cup, which can be read using a QR code or RFID tag, efficiency at large events is increased enormously. The technology not only optimises the return of the cups, but also the entire recycling process, thus making an important contribution to the Circular Economy.
AI is revolutionising modern industry. Thanks to it, complex processes can be automated or efficiency increased. In the plastics industry, AI not only plays a decisive role in the optimisation of production processes and the development of new materials. It also enables more precise waste sorting and therefore better recycling – a benefit for the environment!
The forthcoming EU packaging regulation is casting its shadow: minimum quotas for recyclates are putting the plastics industry under pressure. Cirplus presents a digital platform that not only makes the recyclate market transparent, but also enables real-time coordination between the players.
Profitability and sustainability are not opposites – on the contrary! KraussMaffei's lifecycleValueCalculator proves it: the digital tool calculates the current status of plastics processors' products and shows them their individual potential for improvement. This enables them to increase their production efficiency and achieve their ecological goals at the same time.
The Reifenhäuser Group uses R-Cycle, a digital product passport for plastics based on GS1 standards, to enable its customers to trace products. This facilitates data management in the manufacturing process and promotes the recycling of plastic packaging.
Discover the future of the circular economy at the Circular Valley Convention, premiering on March 12 and 13, 2025, at the Areal Böhler in Düsseldorf.
The Circular Valley Convention will take place for the first time in Düsseldorf on 12 and 13 March 2025.
This innovative convention format, consisting of a conference, expo, and event, is organized by Messe Düsseldorf in cooperation with the Circular Valley Foundation and the Fraunhofer UMSICHT Institute. The CVC serves as a content hub for the circular economy and a marketplace for circular competencies, such as product design, production, logistics, usage, collection, sorting, and recycling.
Top decision-makers from business, science, politics, and society will come together across industries to network and actively shape the transformation towards a circular economy.