Scientific study paves way for new LCA simulation tool from Polykemi Group

Polykemi Group is making a major investment to help companies reduce their carbon footprint. The company is using a scientific study to provide customers information on how their material choices affect the climate.

“We help our customers make smarter material choices to reduce their carbon footprint, while also providing the possibility to make their products lighter and saving both time and costs,” says Sustainability Specialist Henrik Palokangas.

In 2015, the UN adopted a new international treaty on climate change, the Paris Agreement, which strives to limit global warming. To meet the demanding goals, both producers and consumers need to contribute.

“The current discussions is very much focused around energy and fuels, but we also need to consider how different products affect our environment even when they are being produced,” explains Henrik Palokangas, Sustainability Specialist for polymers at plastics manufacturer Polykemi Group, based in Ystad, Sweden.

“We have conducted a scientific study, analyzing the climate impact of all our products and used the results to develop a simulation tool. This gives our customers a unique opportunity to take greater responsibility for the climate, all while reducing their costs.”

Simulation tool calculates materials’ carbon footprint

The scientific study was conducted at Polykemi Group in 2020 and focused on analyzing the climate impacts of the company’s materials. The study demonstrates that the choice of material has a significant part to play in the fight against climate change and assists customers in making smart material choices.

“The simulation tool enables us calculate the cradle-to-gate carbon footprint of all our materials. This enables our customers to assess the environmental footprint of the components they produce,” Mr. Palokangas says.

“It’s easy to select materials out of force of habit, even though there may be significantly better alternatives available that would reduce costs, save time and lower the carbon footprint. We can demonstrate the difference material choices make and help select an optimal alternative in terms of customer requirements, costs and climate performance. “

The scientific study at Polykemi Group was conducted in collaboration with a third party to ensure an objective analysis according to applicable standards. The Life Cycle Assessment (LCA ISO 14040) methodology was used to quantify the environmental aspects of existing or planned products.

Similar studies are currently ongoing for the production unit in Kunshan, China and are planned for the new factories in Chongqing, China and in Charlotte, North Carolina, USA.

The right material for the right purpose – part of the solution

For any finished product on the shelf, between 60 and 80 percent of the carbon footprint originates from the raw materials it is produced from. That is why manufacturers have a responsibility to choose the best materials for their product in terms of function, weight and carbon footprint. In many cases, the carbon footprint can be reduced significantly by selecting plastic instead of, for instance, metal.

For example, the carbon footprint of a stainless-steel salad bowl is 2.4 kg CO₂ more than a bowl of the same size made of polypropylene (PP). This means PP is 10 times smarter material-wise because of its lower carbon footprint and its lower weight.

Another example is a curtain rod consisting of a 3×5 cm aluminum profile. Changing from aluminum to ABS will reduce the carbon footprint by 12 kg per product meter.

“This is a choice that makes a huge difference if an entire office complex is furnished with curtain rods. We believe that companies and producers need to take more responsibility and keep consumers informed so they can make the right choices for the good of the climate,” says Mr. Palokangas.

Lower carbon footprint while saving money

According to Polykemi Group’s scientific study, changing from the virgin material PA6 GF15 to PP GF15, which is technically possible in many applications, will reduce the carbon footprint by 6.9 kg of CO₂e for every kg of material, i.e. 75 percent. If a recycled PP is an option, the carbon footprint can be reduced by yet another 75 percent.

“Even virgin materials can provide significant climate savings. In addition, there is a lower density, which means that we can produce 15-20% more details on each kilo of material. This gives both increased profitability and enhanced climate performance,” says Mr. Palokangas.

For more than 50 years, Polykemi Group has successfully produced and developed customer adapted plastic compounds, from both virgin plastic and high-quality recycled plastic materials.

“Polykemi Group has extensive experience in both virgin and recycled materials, and now also has the possibilities to simulate the effects of material choices,” says Mr. Palokangas.

“Our solid know-how enables us to develop optimized materials in terms of climate performance, features and costs. When used correctly, these three parameters can be aligned to produce the best results.”

Materialsmart.info

To further show how Polykemi Group can help its customers choose the most optimal material for the right application, the new landing page materialsmart.info is now available. In a simplified version of Polykemi Group’s calculation tool, visitors can simulate different material choices and see what impact they have on the climate. In a Quiz, the visitors can test their the knowledge in material selections. There are also examples of different material-smart projects where large savings have been made.

Contact

For more information, please contact:
Henrik Palokangas  
+46 (0) 411 79780 
henrik.palokangas@polykemi.se

About Polykemi Group 

Polykemi AB is based in Ystad, Sweden, and has since 1968 successfully
developed and manufactured customer adapted plastic compounds.

Polykemi Group consists of the companies Polykemi AB, Rondo Plast AB and
Scanfill AB, all based in Ystad, as well as Polykemi Compounds Kunshan in
China, and Polykemi Inc in the USA. Since its inception, the family-owned
business has helped numerous customers in a wide variety of fields to select
the right materials for their specific products.

Polykemi Group provides customers all over the world with customized
plastic compounds based on both virgin and recycled raw materials of the
highest quality.

The first COMPLUS Concept from Rondo Plast and
Polykemi focuses on a newly developed PP-based material for complex interior automotive applications.

The newly developed and virgin raw material based compound POLYfill PP EP317R UV has both high scratch resistance and UV stability, together with excellent mechanical properties and unlimited colouration possibilities. These features makes the material an optimum choice for interior automotive applications.

The material also has three new siblings right from the start, all with similar characteristics and properties that are adapted to the requirement profiles of different parts in an assembled product.

– The idea came up during a conversation with one of our end customers, being one of the world’s largest vehicle manufacturers. They were looking for materials with similar properties, both based on virgin plastic raw material and on high-quality recycled plastic raw material. In some cases, the requirements profile only allows plastic compounds based on virgin plastic raw material, but in other cases, material based on high-quality recycled plastic raw material is the best solution, explains development manager Anette Munch Elmér.

Door panels as an example of a suitable application

The newly developed materials are presented in the new material concept that Polykemi and Rondo Plast have informed about recently. The COMPLUS Concept offers choices between several different materials, both based on virgin plastic raw material and on high-quality recycled plastic raw material. The materials have similar properties but are adapted for different injection molded parts within the same construction.

An example within the automotive industry are door panels, which are often complex assemblies consisting of several parts, all with their individual specific requirement profiles. In this application, all four material alternatives within the COMPLUS PP Concept can be used.

The main components of a door panel, the carrier and the side pocket, are usually parts with a grained surface, produced in many different colors. These parts can often be exposed to both harsh handling and tough sunlight.

According to Polykemi, the optimum material choice is the POLYfill PP EP317R UV with its high scratch resistance and good UV stability. For the same parts, you can also choose a REZYcom material based on high-quality recycled raw materials, with all the environmental benefits it provides, available in dark grey or black colours.

A door panels armrest and door insert are parts often covered with foil, fabric or leather. Here, a third material alternative is available, since the demands for colourations, scratch resistance and UV stability are lower. If the requirement profile is marginally decreased, there is a fourth material alternative, also based on high-quality recycled raw materials.

Flexibility even late in the project process

The concept of COMPLUS PP means that you can choose the right material for the right parts. But even if you have made a correct material choice, the conditions can still change during the course of a project. Then there is the unique opportunity to choose another of the four materials late in the process, since the characteristics and properties are so similar, without having to modify or change the moulds – a fact that saves both time and money.

– The material change can be done without jeopardizing either mechanical properties or quality, the materials are quite simply exchangeable. This is the concept we have now developed, explains Anette Munch Elmér.

The increasing environmental challenges of the future

Polykemi is also working on an initiative related to materials and sustainability, that will be presented shortly.

– We see a future where flexibility in material choices and, above all, everything surrounding sustainability is ever increasing. The use of recycled materials has historically been initiated mainly for financial reasons, but with today’s strong environmental focus, the materials’ CO2 footprint is the most important feature, says Mattias Persson, Sales manager at Polykemi.

– Therefore, we are quite proud to be able to present a precise system for calculating and reporting the CO2 footprints for our materials, in the near future. Calculations will be available for both materials based on virgin plastic raw materials as well as high-quality recycled raw materials, Mattias Persson concludes.

Polykemi and Rondo Plast presents the COMPLUS Concept, giving multiple choices of several materials, based on both virgin and recycled raw materials. The compounds all have similar properties but are adapted for different injection moulded parts within an assembled product.

In the various COMPLUS Concepts, which will be presented shortly, high flexibility is in focus. The compounds, coming from the same material group, are based on virgin raw materials or high quality recycled raw materials and have similar properties and characteristics. This means that the customers have multiple choices of plastic compounds to reach optimum solutions, depending on what properties is needed for the different parts. When using the COMPLUS Concept, you can choose the right material with the right properties for each part.

– One example within the automotive industry are door panels, being complex assemblies of numerous parts. Each part has an individual demand profile to be fulfilled. Here you can use the materials from the COMPLUS Concept for the different parts, explains project manager Mr. Johan Svenmo.

Exchangeable material choices within the development work

Even if you initially have made a correct material choice for a part, the conditions might still change during a project. On these occasions, there is the unique opportunity to be able to choose another material from the COMPLUS Concept, without having to modify, change or even produce a new mould, which saves both time and money.

– Our new concept gives the customers an incredible flexibility even far into a project, and the choice of materials can be adapted during the development work without the costs increasing dramatically. This ensures that the customer can reach the project’s goals faster and in a safer way, says Johan Svenmo.

The first example of the COMPLUS Concept from the POLYfill (PP) and REZYcom (PP) families will be launched soon. Over time, the same concept will also be available for other product families, such as POLYblend (PC/ABS) and SCANAMID (PA).

From some of us to all of you – Happy holidays from Polykemi Group!

Now when this very different year of 2020 finally is approaching its end – we believe more than ever that it´s important to send some friendly holiday greetings to you from your friends at Polykemi Group. 

Check out our holiday season greeting video and follow the flying Christmas gift!

This year’s Christmas gift

Once again, we have chosen to give donations to three helping organizations, instead of company Christmas gifts.

Bris – Children’s Rights in Society

A children’s rights organization that listens to, supports and strengthens children and young adults’ rights in society. Read more about Bris here  →

The Swedish Childhood Cancer Fund

The Swedish Childhood Cancer Fund works to fight childhood cancer and ensures that affected children, youth and their families receive the care and the support they need. Read more about the Swedish Childhood Cancer Fund here  →

MSF – Doctors Without Borders

Médecins Sans Frontières (MSF) is an international, independent medical humanitarian organisation that provide medical assistance to people affected by conflict, epidemics, disasters, or exclusion from healthcare. Read more about MSF here  →

Opening hours during the holidays

Finally, we would like to inform you all that the production will close down for maintenance and holiday celebrations on December 23 2020, restarting again on January 11 2021. Within the working days of this period (December 23, 28-30 2020 and January 4-5, 7-8 2021) some staff at the transport and sales departments will be at your service.

Looking forward to connecting with you all again in January 2021!

In mid-November, it’s time for the well-attended fair Elmia Subcontractor in Jönköping and Rondo Plast are represented with our own booth together with the environmentally friendly super hero Rondoman.

We will highlight the recycled and customized REZY program as well as the new investment in more dark shades.

– In addition to the technical performance, we have extensive experience of working with customized shades in the black and dark gray color scale, explains Fredrik Holst.

He says that the right choice of raw materials and a long experience in coloring gives Rondo Plast the opportunity to offer several shades of black and gray, all according to the customer’s wishes, without compromising on sustainability, quality or mechanical performance.

– Welcome come to our booth and discuss recycled plastic with us. As a wholly owned subsidiary of Polykemi AB, we at Rondo Plast have both the knowledge and experience to solve new challenges and we can help customers both in the national and international market, says Fredrik Holst.

Elmia Subcontractor runs in Jönköping between November 12 and 15, 2019. Rondo Plast can be found in booth B03:58.

In our world – things are not all black or white

To make a choice can sometimes be difficult. If the choice needs to be environmentally friendly, sustainable, aesthetically appealing and with a cost awareness, it can be even more difficult. But now and then, it can be really easy to make the right choice. Like with REZYcom – our customer adapted eco-friendly material grade, based completely or partly on recycled plastics. A great opportunity to make a maximum impression with minimal environmental footprint, without any compromises in neither quality nor sustainability. A fact we are very proud of and can put our signatures on – in black and white , even in shades of grey.

Rezycom strengths

Custom-made shades of grey

The right choice of raw material and extensive experience in coloring of plastics makes it possible for us to offer multiple shades of black and grey, according to customers’ requests.

High mechanical performance

Numerous reinforcements are available and different choices provide different mechanical properties for the plastic product. With our experience and knowledge, we are able to make the correct choices, which results in a recycled material comparable to compounds based on virgin raw material.

Optimal product lifespan

Rays of sun, strong detergents or high surrounding temperatures can severely shorten the lifespan of plastic products. However, the correct combination of additives makes it possible to optimize its lifetime.

Quality in – quality out

We choose our suppliers and sources of recycled plastics with great care. We evaluate the sources continuously, since quality is of utmost importance to us. We know it takes high quality raw materials to produce and deliver high quality products. And that is something we do. Because we can.

Long experience of sustainable plastics

Polykemi Group produces and delivers high quality, sustainable compounds of recycled plastics for injection moulding and extrusion. Apart from the customized program REZYcom, we also have REPRO – our standard range of black recycled plastics. With headquarters in Ystad, Sweden, we have over 50 years of experience of compounding and are represented on three continents.

REZYcom – our customized program of sustainable materials for a sustainable future.

Nationally, Rondo Plast is one of the major advocates for sustainable materials. Now, we push for the recycled plastic globally, by speaking at a seminar in China.

In 2018, Volvo Cars’ ambition was announced that at least 25% of the plastic in their cars should be made of sustainable material by 2025. Ystad-based Rondo Plast is a central partner for the internationally renowned car manufacturer. This gave Rondo Plast the opportunity to showcase the project in China.

– Thanks to our good cooperation with Volvo Cars, we had the opportunity to push for the recycled plastic in China as well, says Fredrik Holst, Product Manager at Rondo Plast.

Rondo Plast, which is part of the Polykemi Group, was invited to the China Plast fair and Fredrik Holst was one of the speakers at the seminar Plastic Recycling & Circular Economy Conference & Showcase. The seminar discussed sustainability issues and what opportunities there is with recycled plastic raw materials.

– In Sweden and Europe, recycled consumer plastic is a well-known concept, but in Asia today, industrial waste constitutes a larger proportion of the recycled material. Therefore, it was interesting for us to be active in the discussion about how to bring consumer plastic back to the industry and what opportunities exist in the future, explains Fredrik Holst.

– It is our absolute intention to continue to be a global supplier of high quality recycled materials. The seminar in China provided a great opportunity to share our experiences and hopefully open up for a discussion about the material of the future in the Asian market.

Rondo Plast unterstützt die Zielsetzung von Volvo Cars, bis 2025 mindestens 25% des Kunststoffs in den Modellen aus nachhaltigem Materialien herzustellen. Das Demonstrationsfahrzeug von Volvo Cars, welches in diesem Sommer vorgestellt wurde, verdeutlicht Volvo Cars Engagement für diesen Anspruch, der von allen Premium-Automobilherstellern am fortschrittlichsten ist.

Von Beginn an ist Rondo Plast in das Projekt involviert und als wichtige Schnittstelle sowohl Ansprechpartner für den Spritzgießer als auch für Volvo Cars, um Ansätze von der Machbarkeit her zu diskutieren, Lösungen vorzuschlagen und umzusetzen. Rondo sieht durch die Teilnahme an diesem ambitionierten Projekt große Chancen für die Zukunft des Unternehmens und das breite Wissen auf dem Recyclingsektor von Rondo Plast und der gesamten Polykemi Group zu demonstrieren.

– Das neue Modell wird auf dem bestehenden Volvo XC 60 basieren. In diesem Projekt wird eine Anzahl von verbauten Kunststoffteilen mit einem Gewichtsanteil von 60 kg auf rezyklierte Kunststoffe umgestellt. Als Compounder sind wir seit Beginn der Entwicklung des Autos involviert, so Fredrik Holst, Produktmanager bei Rondo Plast.

Rondo Plast Produktmanager Fredrik Holst bei der Enthüllung des Concept Cars beim Volvo Ocean Race in Göteborg, Schweden.

Die Rohstoffe für die recycelten Kunststoffcompounds von Rondo stammen sowohl aus Industrie- als auch aus Verbraucherabfällen. Jede Charge durchläuft vor dem Einsatz in der Produktion die strengsten Qualitätsvorgaben und Prüfungen der Qualitätssicherung. Im Concept Car kommen die Rondo Compounds in Luftkanälen, der Mittelkonsole hinter Radio und Display, den Radhausschalen, der Ladeflächenabdeckung, aber auch in vielen anderen Anwendungen, zum Einsatz.

– Unsere Materialien werden häufig in tragenden und technischen Bauteilen eingesetzt, die später mit einem Oberflächenmaterial überzogen und veredelt werden, so die weiteren Informationen von Fredrik Holst. In diesen Komponenten liegen die besten Chancen für Volvo Cars das ehrgeizige Ziel zu erreichen, dass bis 2025 mindestens 25 % des Kunststoffanteils in den Autos aus recycelten Rohstoffen bestehen.

– Wir ziehen den Hut vor Volvo Cars, den unseres Wissens nach ist Volvo Cars der erste Fahrzeughersteller im Premiumsektor, der diese Position offiziell einnimmt. Unser Bestreben ist auch weiterhin, der Partner für qualitätsgesicherte Compounds auf der Basis ganz oder teilweise recycelten Rohstoffen zu sein, fast Fredrik Holst abschließend zusammen. Lasst uns den Weg gemeinsam weitergehen!

Rondo Plast liefert Recycling-Compounds für Kunststoffteile, die im Demonstrationsfahrzeug von Volvo verwendet werden. Bild zeigt die Qualitätssicherung.

Presseveröffentlichungen:

Plasticker

K-Aktuell

Kunststoff Web

K-PROFI

EPPM (Englisch)

British Plastics & Rubber (Englisch)

Plastech (Englisch)

Plastic Portal (Englisch)

Composite Solutions Magazine (Englisch)

Environment, recycling and a sustainable future. These were the key words when Rondo Plast exhibited at Elmia Subcontractor for a third year with our own stand concept.

The eco-friendly superhero Rondoman welcomed in booth B03:58 and he opened up for a nice and rewarding discussion. In a relaxed environment, there were opportunities for interesting and inspiring meetings where our other superheroes Fredrik, Dennis and Patrik could explain how companies can become environmental heroes by using recycled plastic.

Thank you for all visits in our booth!

Rondo Plast, together with Polykemi, presented exciting products at Sweden’s largest plastic fair Elmia Polymer, which took place between 15-18 May 2018 in Jönköping. We had a common booth that we shared with colleagues from the parent company Polykemi.

Our product manager Fredrik Holst attended the Recycling Day and informed about challenges and opportunities regarding recycled plastic raw material.

Rondo Plast AB delivers recycled material to HÅG´s (a part of Scandinavian Business Seating) office chair named Capisco. The Capisco office chair is already unique carrying the nordic ECO label called the swan and now in addition the Capisco has received an award at IdentiPlast 2015 in Italy Rome, where EPRO (European Association of Plastic Recycling and Recovery Organisation) awarded the office chair first price being the most innovative and inventive use of recycled plastics in Europe 2015.

See link to press release from rigk.com
Read more…

See link to german website www.plasticker.de
Read more…

See link to Chech/Slovak website www.plasticportal.eu
Read more -text in slovak language…

See link to German magazine Kunststoff-magazine.de – issue 05/06
See page 53