PET Value Chain Unlocking the Potential - Real ... · PET Value Chain: Unlocking the Potential ......
Transcript of 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
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
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
1. Brief Overview of European PET film industry
Statistics:
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
1. Brief Overview of European PET film industry
Process to produce polyester films: Cast Films (APET)
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
1. Brief Overview of European PET film industry
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
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
1. Brief Overview of European PET film industry
Process to produce polyester films: Oriented Films (OPET)
Source: www.brueckner.com
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
1. Brief Overview of European PET film industry
Process to produce polyester films: Oriented Films (OPET)
Source: www.brueckner.com
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
1. Brief Overview of European PET film industry
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
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
1. Brief Overview of European PET film industry
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%).
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
2. Comments on Biopolymers
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
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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.
2. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
source: Ecoflex-brochure
2. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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
2. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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
2. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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 - / + +
2. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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!
2. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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
2. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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.
2. Comments on Biopolymers
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
3. Sustainability in Practice
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!
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
Foamed APET
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
Foamed APET
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
Foamed APET – Cost savings
3. Sustainability in Practice
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.
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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!
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
THE EFFECT OF USING RECYCLED
MATERIALS
ON CARBON FOOTPRINT
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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.
3. Sustainability in Practice
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
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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
3. Sustainability in Practice
2.26 MT CO2 E/Short ton
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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!!
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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!
3. Sustainability in Practice
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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!
3. Sustainability in Practice
4. BUERGO.FOL
www.buergofol.deBUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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
BUERGOFOL GmbH � · Jahnstraße 10 · 14 � D-93354 Siegenburg
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 · 14 � D-93354 Siegenburg
BUERGOFOL GmbH
Jahnstraße 10-1493354 Siegenburg Germany
Fon +49 (0) 94 44 / 97 91-110Fax +49 (0) 94 44 / 97 91-55
CONTACT