Driving Circularity in Durable Plastics

Durable plastics play an integral role in modern society, but their durability challenges their recyclability and end-of-life.

Durable plastics are integral in vehicles, buildings, electronics, and medical devices. These materials offer exceptional performance, longevity, and design flexibility, making them indispensable in various industries. However, the durability that makes these plastics valuable also presents significant challenges, particularly regarding end-of-life (EOL) sustainability and recycling. Addressing these challenges is critical for advancing sustainability and circularity in durable plastic markets.

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Recognizing this need, the American Chemistry Council published an industry roadmap for actions to advance sustainability and circularity for durable plastic goods.

Challenges in End-of-Life Management

One of the primary issues with durable plastics is their complex EOL management. Durable plastics, designed to last for many years, are difficult to break down and repurpose, unlike single-use plastics, which are easier to recycle. Each market sector that relies on durable plastics faces unique challenges in improving sustainability and circularity. For instance, the automotive industry focuses on increasing the use of recycled plastics, developing business models that support recycling, and meeting global circularity standards. This approach reduces waste and contributes to a more sustainable production cycle.

Sector-Specific Strategies for Durables

In the building and construction sector, the emphasis is on modular design, deconstruction methods, and advanced recycling techniques.

These strategies aim to improve the circularity of materials used in construction, ensuring that buildings can be more easily disassembled and their components reused or recycled. On the other hand, the electronics industry faces its own challenges, particularly in extending the lifespan of products and improving recycling infrastructure. Establishing recycling standards and backing right-to-repair legislation are vital measures that promote the reuse and recycling of electronic components, ultimately decreasing the need for new raw materials. For instance, Microsoft designed its Surface Hub 2S with modular components to facilitate repairs and upgrades. Similarly, Epson, a leading global printer manufacturer, aims to become “underground resource-free” by 2050.

Automotive Industry Initiatives

BMW, Audi, Toyota, and BASF are advancing sustainable automotive design, each focusing on different aspects of recyclability and innovation.

• BMW’s i Vision Circular concept vehicle highlights designing with the end of life in mind. It features an interior crafted from monomaterials that are connected without bonding, simplifying disassembly and ensuring material purity. This approach makes the recycling process more efficient.
• In contrast, Audi has partnered with the Karlsruhe Institute of Technology to address mixed end-of-life automotive plastics through chemical recycling. Their process converts these plastics into pyrolysis oil, which can be reused as a valuable resource in new production cycles.
• Toyota Motor Corporation is also embracing sustainability by integrating bioplastics into various vehicle components. For instance, seat cushions in several Toyota models use plastics that are fully or partially derived from plant materials. Toyota also incorporates post-industrial cotton and synthetic fibers from garment clippings into door panel insulation, floor silencers, and floor mats. This strategy reduces waste and promotes a circular economy, aligning with broader sustainability goals.
• Simultaneously, BASF has achieved a significant advancement in Europe by commercializing Mercedes door handles made from chemically recycled and renewable feedstock. This innovation underscores the industry’s shift towards integrating recycled materials into high-quality automotive components. Collectively, these efforts highlight the automotive industry’s commitment to using more sustainable and recyclable materials in vehicle production.

Collaboration and Legislative Drivers

Due to their longevity, durable plastics are being increasingly adopted in infrastructure projects like pipelines and bridges. However, the challenge remains in effectively recycling and reusing these materials at the end of their life cycle. Similarly, the medical sector innovates with biocompatible and sterilizable plastics while also exploring the development of greener, recycled alternatives to reduce environmental impact.

Beyond environmental benefits, there are also significant economic incentives for recycling durable materials. For instance, the vehicle recycling market is expected to grow by 15.2% annually from 2022 to 2028, expanding from $72 billion to $160 billion. This growth underscores the financial viability of recycling durable plastics, further driving industry efforts toward sustainability.

Moving Towards a Circular Economy

To address these challenges, collaboration between industry and government is crucial. Legislative drivers like the Green New Deal for Health push for greater use of recycled materials. Similarly, EU Vehicle Circularity Requirements encourage sustainable practices across various sectors, aiming to standardize efforts. The roadmap for advancing sustainability in durable plastics calls for more investment in recycling infrastructure and the development of new technologies.

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