pet value chain unlocking the potential - real ... · pet value chain: unlocking the potential ......

Dr. Kurt Stark March 14th, 2013

PET Value Chain: Unlocking the Potential

Thursday 14th – Friday 15th March 2013

Movenpick Amsterdam City Centre, The Netherlands

Developments in the European PET film industry:

Real Sustainability with foamed APET Films

Contents

1. A brief overview of the European PET film industry

2. Comments on Biopolymers

- Overview- Disadvantages- Labelling- (Negative) Press

3. Sustainability in Practice

- Foamed APET- Advantages- Cost savings- Composite Films- Recycling- Summary

4. BUERGO.FOL

www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg

1. Brief Overview of European PET film industry



Statistics:

Germany: about 12 Mio to/a



Statistics:



Process to produce polyester films: Cast Films (APET)



Process to produce polyester films: Cast Films (APET)

Source: © 2013 Eastman Chemical Company

Cast Films (APET) from BUERGOFOL

Colouring available · easy peel · reclosable ·anti-static/anti-block · UV protection

OPTIONS

RIGID FILMS / RIGID FILMS FOAMED• BUERGO.PET / BUERGO.PET EXPANDED

PET rigid films



Process to produce polyester films: Oriented Films (OPET)

Source: www.brueckner.com



Some OPET Film producers in Europe:

Mitsubishi Polyester Film Europe -http://www.m-petfilm.com/Europe/default.htm

DuPont Teijin Films Europehttp://europe.dupontteijinfilms.com/

NUROLL SpAhttp://www.polinas.com.tr/nuroll/

Toray International Europe GmbHwww.torayfilms.eu



Market of BOPET Films:

Source: http://www.ihs.com/products/chemical/planning/ceh/polyester-film.aspx

Packaging represents the largest end-use market for BOPET film (48%), followed by industrial (24%) and electrical/electronic (12%).



Overview

Not compostable compostable

Renewable resources

Oil based materials

PVOH

LDPE, LLDPE, HDPE,

PET, PP, PA, PS, COC,

SOPP, EVOH, Oxo-

Degradable Blends

Ecovio

Polycaprolactone

X

X

Bio-PE, Bio-PP

Bio-PA

Celluloseacetate

Polyisoprene

PLA

TPS

PHB

Cellophane

Blends


Disadvantages

1. NatureWorks – PLA (Polylactic acid)(http://www.natureworksllc.com/)

- Volume in 2012: appr. 300.000 to/a (totally)

- Price between 1,1 €/kg up to 4 €/kg

- Price is fluctuating. Depends on size of customer.

- Smaller companies often get a higher price � Market entrance difficult!

- Almost no alternatives to biobased polyester = polylactic acid

- Difficult to process! Very moisture sensitive and hygroscopic!

- Based on genetically modified corn!

Only few supplies.

They often have a monopoly.



2. BASF – Ecoflex / Ecovio (http://www.plasticsportal.net)

- Price very high, appr. 3.45 €/kg

- Almost no alternatives for Ecoflex / Ecovio

- Ecoflex is an aliphatic-aromatic Copolyester based on oil

- Ecovio is a blend of 55 % Ecoflex and 45 % PLA � Processing is ok

Disadvantages

Only few supplies.

They often have a monopoly.



source: Ecoflex-brochure



Limited availability of Biopolymers

Very high price (up to factor 6!) compared to oil based polymers

PLA: produced in the U.S. from genetically modified corn

Compostibility is indeed advertised, but not industrially practisedas this happens unsatisfactory and needs too much energy (temperatureabout 75°C, defined humidity, duration several weeks � takes too long!)

Eco bilances / life cycle assessments are often sugar coated and green washed!

Disadvantages



Packages made from Biopolymers are NOT RECYCLED, but incineratedinstead! This is also what experts recommend. (s. Hans-Josef Endres, Andrea Siebert-Raths, „Technische Biopolymere“, Carl Hanser Verlag München, 2009, S. 256)

Serious deficits regarding material properties:

- no barrier against oxygen and water- too brittle- water sensitive and hygroscopic- poor sealing properties (especially when based on cellulose)- Processing is very difficult (machines have to be modified!)- not temperature stable (for PLA, < 60°C)- additivation is necessary!

Made from food of man and beast!

Disadvantages



Overview of advantages and disadvantages of Biopolym ers in 2013 – Example PLA

++-Barrier to Oxygen/Water

+++- / +Sealing Properties

Property Biopolymers Oil based polymers

Ecology / Sustainability ++ -

Disposal - / + +

Mechanical Properties - +Additives - / + ++

Diversity - ++

Processing - +++Thermal Stability - / + +

Water Sensitivity - +

Thermoforming - / + ++

Odour - / + +



Labelling

20

Organisation DIN-CERTCO / IBAW

AIB Vinçotte BPI / USCC Jätelaito-syhdistys

BPS

Land Germany Belgium USA Finnland Japan

Logo

Standard EN 13432

DIN V 54900

ASTM D6400

EN 13432 ASTM D6400 EN 13432 GreenPLAcertificationscheme

OECD 301C

equivalent to Australian standard AS 4736-2006

Confusion of Consumers because of NOT DEFINED labels:

No consistent certification!



Negative Press:

Danone and DUH (Deutsche Umwelthilfe), 6th of December 2011:

http://www.lockelord.com/qs_2011trademark_packagingawards/

The German Greenwashing Lawsuit

Danone’s inclusion on the packaging of the phrase “new environmentally-friendly tub” raised theire of a German environmental organization, known as DUH, which promptly filed a complaintagainst Danone in the Munich District Court. DUH’s accusations of greenwashing byDanone centered on two supposed environmental deficiencies of the packaging: 1) thenew packaging is not recyclable; and 2) the packaging did not represent an environmentally-discernible improvement over Danone’s predecessor polystyrene packaging because it was made from genetically-modified corn — an environmental no-no in DUH’s estimation.

http://www.duh.de/pressemitteilung.html?&tx_ttnews%5Btt_news%5D=2748

vs. = 1 : 0



Negativ Press: 13th of April 2012

?

http://www.freshplaza.com/news_detail.asp?id=95478#SlideFrame_1

Germany: Discounters present themselves 'greener' than they are

The German environment organisation 'Deutsche Umwelthilfe' (DUH) is of the opinion that the supermarket chains Aldi and Rewe deceive the consumer. They say they sell carry bags made out of organic plastic, which can be composted. According to DUH these bags cannot be composted and are not recyclable. Prints of green landscapes and slogans such as 'Zeig der Umwelt ein Lächeln!' (Show a smile to the world around you!) make the plastic bags of Aldi and Rewe look good. According to the environmental organisation the companies want to give the impression that organic products are involved. However, the DUH came, after research, to a different conclusion: the bags cannot be composted, cannot be recycled and are mainly made out of crude oil. The organisation mentioned consumer deception and 'green washing'. The environmental group will now establish whether legal proceedings can be started.




Foamed APET – APET expanded

� Saving resources and recycling while maintaining its renowned product quality are the goals declared by BUERGO.FOL

� Pioneer in Germany with foamed APET-films in a thickness range of 200 µ to 900 µ

� BUERGO.PET expanded

� Produced on ultra-modern facilities at the Ingolstadt site, Germany

� Weight savings of up to 30% are possible in packaging (compared to not foamed APET films)

� This responsible handling of resources is environmentally friendly since it reduces the overall energy consumption and CO2 emissions

� Sustainability can also be successfully realized with the established petrochemicalbased materials!


Foamed APET



Foamed APET - Advantages

In addition to the saving of packaging weight, foamed APET films have these benefits:

� Very high mechanical strength and robustness

� Perfectly suited for use as a deep draw film on all common thermoforming and packaging plants, even on older models

� Extremely deep recesses can be formed without requiring the use of a stamp

� The structures applied to the thermoforming mold are formed precisely and with detailed contours on the foamed film

� Wear on the cutting knifes is minimized

� Due to the insulating effect, the keeping quality of the packaged productimproves as well

� Visually, the foam structure is very appealing and attractive

� Film and packaging feel soft and smooth in your hand while still providing a good grip

� Available in various colours, and the film can be printed with excellent results



Foamed APET



Foamed APET - USE

The innovative foam films based on polyester are therefore superbly suited for themanufacture

� of trays, tablets, pans, plates, dishes, and cups for the food area

� as well as for the non-food area

� Packaging foods such as meats and sausages, cheese, snack items, fish and seafood, poultry, baked goods and ready-made meals

� Packaging of consumer and industrial goods such as hygiene products, household goods, office supplies, electronics



Foamed APET – Cost savings


The table shows how much packaging material weight can be saved when using the foamed film. In addition to the cost savings in material and the lower transportation costs resulting from the lower packaging weight, it is also necessary to consider the not-so-insignificant savings in DSD (dual refuse system) fees for the “Green Point“ system.


Foamed APET – Combination with barrier films from BUE RGOFOL to Composite Films

Festverschluss APET; RCHigh barrier40 to 150T 678

PP homo, random, CopoHigh barrier35 to 100T 713

Safety peelHigh barrier25 to 140 KF 08

High hot tack

Flowpack

High barrier25 to 140 KF 02

KF 03

Laminating films

Transparent and with colour

antistatic

UV-Blocking

antifog

Combinations

PE, PP

Multipeel APET, PP, PS (mono)

Safety peel, Easy peel

Reclose (RC)

High barrier25 to 140 T 900

TypesSealing materials/substrates

Specialities

PropertyThickness µProduct



Foamed APET – Composite Films

Advantages of Composite Films with foamed APET-Films:

� No Delamination! Inseparable!

� Barrier properties can be adjusted against:

� Oxygen� Water� Carbon Dioxide (CO2)� Aggressive Chemicals

� Variation of opening characteristics of the packaging:

� Easy Peel� Peel� Safety Peel� Tight sealing� Reclose

� Tailor-made solutions!



THE EFFECT OF USING RECYCLED

MATERIALS

ON CARBON FOOTPRINT



There is not any method available for recycling biomaterials.

In contrast: If large amounts of PLA were to be sent to the recycling plant, then the raw materials would contaminate the waste stream and make other recycled plastics unmarketable.

Based on a report from the experts at Euwid, the Petcore organization views the recycling of PET bottles to be at risk.

Even a small market share of PLA could lead to a serious disruption of the infrastructure for recycling PET bottles in Europe.


Risks when recycling Biopolymers, like polylactic acid (PLA):

Source: http://www.innovations-report.de/html/berichte/studien/bericht-109058.html

Gunnar Sohn | Quelle: pressetext.deutschlandWeitere Informationen: www.petcore.orgwww.euwid.dewww.plasticsconverters.eu


Recycled materials - Date: 02-29-2012

1.01 MT CO2 E/Short ton

Source: United States Environmental Protection Agency –http://www.epa.gov/http://www.epa.gov/climatechange/wycd/waste/downloads/Plastics.pdf


2.26 MT CO2 E/Short ton


Recycled materials vs. Biomaterials – Scenario: Inciner ation with heat Recovery

http://www.natureworksllc.com/the-ingeo-journey/Eco-Profile-and-LCA/Life-Cycle-Analysis/Clamshells_rPET.aspx

Be careful: Study was paid by NatureWorks!

EVEN NatureWorks states: „ We agree that the use of rPET is a better way of doing business as usual“!

BUT: rPET is as good as PLA!!



Our foamed APET film consists mainly or entirely of recycled materials:

� recycled APET (bottle grade)

� agglomerated recycled special polymers

Only 1,01 kg CO2 eq. / kg polymer !!!

BETTER THAN PLA FILMS MADE OF RENEWABLE RESOURCES!



Summary:

� Be careful with LCA of PLA – has been made from the supplier NatureWorks!

� LCA data may be different according to scenarios and assumptions used

� BUERGO.FOL is mainly or entirely using recycled materials !!

� Materials from trimmed edges or punch scraps are 100 % reused and put back in the cycle

� In addition, foaming saves up to 25 % of weight and is even more sustainable!


4. BUERGO.FOL


COMPANY / BRIEF PROFILE

CORE COMPETENCY

UNIQUE SELLING POINT

SPECIALTY

SITES

EMPLOYEES

CERTIFICATIONS

40 years of experience in the co-extrusionof composite films

Development of film recipes to suit theapplication or customer request

High-barrier EVOH-based films,printed and unprinted, as well as rigid films

Siegenburg, Ingolstadt, Neutraubling

Around 300

DIN EN ISO 9001:2008, HACCP,BRC/IoP Global Standard Version 4, ISO 50001

SIEGENBURG, Bavaria, GermanyHeadquartersFlexible films

INGOLSTADT, Bavaria, GermanyRigid foil factory

NEUTRAUBLING, Bavaria, GermanyCentre of excellencePrinting and laminating

COMPANY / LOCATIONS

www.buergofol.de

• BLOWN-FILM EXTRUSION

- Capacity: 15,000 tons per year

· 1 x 3 layer· 3 x 5 layer· 3 x 7 layer· 2 x 7 layer shrink-wrap film machines

• CAST FILM EXTRUSION (APET)

· Capacity: 25,000 tons per year· 3 machines

• Printing • Laminating • Cutting/Winding • Pouch customising

COMPANY

TECHNOLOGY / EXTRUSION MACHINES

BUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg

www.buergofol.de

• FOODSTUFFS

• TECHNICAL APPLICATIONS

• MEDICAL PRODUCTS

• PET FOOD

• CHEMICAL INDUSTRY

• SPECIAL APPLICATIONS

APPLICATIONS / MARKETS


www.buergofol.de

• TUBULAR POUCHES, TOP FILMS AND BAGS• BUERGO.FLEX FLOW / TOP, BUERGO.BAG

• BOTTOM FILMS• BUERGO.FLEX BOTTOM

• TOP FILMS• BUERGO.FLEX TOP

• LAMINATES / RECLOSABLE• BUERGO.FLEX SPECIAL / BUERGO.RECLOSE

• RIGID FILMS / FOAMED RIGID FILMS• BUERGO.PET / BUERGO.PET EXPANDED

• SKIN FILMS• BUERGO.SKIN

• SHRINK FILMS• BUERGO.SHRINK

• SPECIALISED FILMS• BFCR

PRODUCTS


BUERGOFOL GmbH

Jahnstraße 10-1493354 Siegenburg Germany

Fon +49 (0) 94 44 / 97 91-110Fax +49 (0) 94 44 / 97 91-55

[email protected]

[email protected]

CONTACT

pet value chain unlocking the potential - real ... · pet value chain: unlocking the potential ......

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