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!

During September 2020, an art exhibition was held in Malmö, where the purpose was to draw attention to society’s major sustainability challenges related to plastic, especially what opportunities there are on how to face them. Rondo Plast sponsored the exhibition with several different recycled materials.

It is easy to dismiss plastic as a material that only causes problems. But plastics also have an important role to play in the transition towards a more sustainable society. We need to broaden our conceptions of plastics, in order to shift perspectives on how we design, produce, apply and use the material.

The artist and designer Kajsa Willner wanted to highlight this in the exhibition Materiality & Aggregation, to in an artistic context inspire and evoke curiosity about plastic, their material properties and their functionality in different applications.

Kajsa Willner built the interpretations and exhibition architecture with the aim of making as little CO₂-emissions as possible, using sustainable materials from local firms. Rondo Plast sponsored the exhibition with several different materials, based on both fully and partially recycled plastic raw material.

The materials were used in a creation in the form of a transparent patchwork with 117 pockets filled with different plastic granules representing the many plastic types available on the market.

Materiality & Aggregation

The exhibition Materiality & Aggregation had its starting point in a discussion brief brought forward by the research program STEPS (Sustainable Plastics and Transition Pathways).

The report addresses how to face society’s major sustainability challenges related to plastics. Designer Kajsa Willner interpreted these challenges in five pathways to a more sustainable plastic society. The five pathways were: reduce use, recycle more, fewer types, bio based plastics and biodegradable plastics. The pathways were interpreted separately in the exhibition, but all together were meant to be crucial in the transition towards a more sustainable plastic future.

– The aim for me as a designer and for this exhibition is to use design as a tool to communicate, to convey academic research in a way that can reach out to a wider audience, says Kajsa Willner.

– In this case it’s about nuancing the public debate around plastic and advocate a more holistic view to how we approach the material.

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A panel discussion was also held during the opening of the exhibition. It included designer Kajsa Willner, representatives from STEPS and Form/Design Center.

The discussion was about how design, academia and the industry can work together for a more sustainable plastics society.

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The exhibition was held between 10-27 September 2020 at Hedmanska gården in Malmö, Sweden, in front of Form/Design Center – a large meeting place for architecture, design and art in southern Sweden.

Read more about the exhibition here  →

Read more about the designer Kajsa Willner here  →

Photographer image 1: Kennet Ruona
Photographer remaining photos: Daniel Engvall

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.

Rondo Plast is supporting Volvo Cars ambition to have at least 25% of the plastic in their cars being made from sustainable material by 2025. The Volvo Cars demonstrator vehicle that was revealed this summer exemplifies their commitment to this ambition, which is the most progressive by any premium automotive manufacturer.

Since the start of the project, Rondo Plast has been a vital partner who discussed and found solutions with both injection moulding suppliers and Volvo Cars. Rondo sees excellent opportunities for the future of the business to participate in this ambitious initiative and to demonstrate Rondo Plast’s broad knowledge in the industry.

– The car originates from the existing XC60 model. Plastic parts corresponding to about 60 kg are replaced by recycled plastic in this project. As a compounder, we have been involved since the beginning of the development of the car, says Fredrik Holst, product manager at Rondo Plast.

Rondo Plast’s product manager Fredrik Holst with the demonstrator car revelation at Volvo Ocean Race in Gothenburg.

The sources of Rondo’s recycled plastic materials derive from both industrial and consumer waste. The materials from Rondo in the demonstrator car are found in air ducts, the central console behind the radio and the display, the wheel arcs, and the loading floor support structure, but also for other applications.

– Our material is often used in load-bearing and technical components which are covered by a surface material, Fredrik Holst continues. It is among these components that Volvo Cars has the best opportunity to achieve their ambitious goal, where at least 25% of the plastic in their cars will be recycled raw materials by 2025.

– We take our hat off to Volvo Cars for being the first vehicle manufacturer in the premium segment to take this stand. It is our absolute intention to continue to be the partner in quality assured compounds based on wholly or partly recycled raw materials, concludes Fredrik Holst. Let the journey towards common goals continue!

Rondo Plast supplies recycled material to plastic parts used in Volvo Cars demonstrator vehicle.

The plastic press informed about this:

EPPM

British Plastics & Rubber

Recycling Magazine

Plastech

Plastic Portal

Composite Solutions Magazine

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

November 2016:
Rondo Plast AB exhibited at the Elmia Subcontractor 2016 –  in a stand of our own!
The follow up work has started!

March 2016:

Rondoplast AB is quality certified conforming to ISO 9001:2008 and environmental certified conforming to ISO 14001:2004 since many years.
You will find the renewed certificates -valid from 28th Februari 2016 under Quality and Environment.

Febr. 2016:

Our new high heat recycle based materials REZYcom PP RT414 VT & RT418 VT also attracts interest within the spanish press.

Se below article from Plasticos Universales – an excellent occassion to practice some school spanish.

Read the article here