1

Plastics – the Facts 2010An analysis of European plastics production, demand and recovery for 2009

2

• Whoweare? Page 3

• Structureofthereport Page 4

• Navigatingthecrisis Page 5

1. Industry overview – Our contribution to wealth and life

• Plastics–providingasafeandsustainablelife Page 7

• Theplasticsindustryplaysanimportantroleinour21stcenturyeconomy Page 8

• Plasticsproduction Page 9

• Plasticsapplications Page 10

• Thedifferenttypesofplastics Page 11

• Globalimportsandexports Page 12

2. End-of-life – Is there life after?

• Ourvision Page 15

• ThefourR’s–Plastics’significantcontributiontothesustainableuseofresources Page 15

• Plastics,valuechainduringitslifecycle Page 16

• Lessandlessusedplasticisgoingtolandfilleachyear Page 16

• Progresstowardscapturingthefullvalueofusedplastic Page 17

• Awardforthebestrecycledproduct Page 18

• Taleof3countrieswithhighplasticspackagingrecyclingrates Page 19

• Vinyl2010 Page 21

• Mechanicalrecyclingofplastics Page 22

• Moreeffectivecatalystsdrivedevelopmentoffeedstockrecycling Page 23

• Energyfromwaste Page 23

3. Innovation

• Transportation Page 25

• Buildingandconstruction Page 27

• Electrical&Electronicequipment Page 27

• Packaging Page 28

• Leisureandsport Page 29

• Healthcare Page 29

• Snapshot2010 Page 30

• Glossaryofterms Page 31

Tableofcontents

Solar Impulse: the first solar aircraft designed to fly day

and night powered by solar energy without any fuel

SolarImpulsepartners:

Solvay:MainPartner

BayerMaterialScience:OfficialPartner

Picturecopyright:SolarImpulse/PoolReutersChristianHartmann

3

Who we are?

TheEuropeanplasticsindustrycontributessignificantly

tothewelfareofEurope.Plasticsdrivesinnovation,

improvesqualityoflife,andfacilitatesresourceefficiency

andclimateprotection.Morethan1.6millionpeople

workinover50,000companies–manyinSMEs(small

andmedium-sizedenterprises)fortheconversionsector

–generatingturnoverintheregionof€ 300billion

peryear.

PlasticsEuropeistheorganisationrepresenting

Europe’splasticsmanufacturers.Itnetworkswith

Europeanandnationalplasticsassociationsandhas

100membercompanies,producingover90%ofall

polymersacrossthe27EUMemberStatesplusNorway,

Switzerland,CroatiaandTurkey.PlasticsEuropeisa

leadingEuropeantradeassociation,withofficesin

Brussels,Frankfurt,London,Madrid,MilanandParis.

EuPC–theEuropeanPlasticsConverters–isthe

professionalrepresentativebodyofplasticsconverters

inEurope.Theiractivitiescoverallsectorsofthe

plasticsconvertingindustry,includingrecycling.Their

mainobjectiveistodefendandpromotetheEuropean

plasticsconvertingindustry’sinterestsby:

• VoicingindustryopiniontoEuropeanand

internationalinstitutionsandNGOs(non

governmentalorganisations)

• Maintainingrelationshipswithcorresponding

Europeanandglobalorganisations

• Conductingsurveys,studiesandresearchprojects

coveringallareasoftheplasticsprocessingindustry

EuPR–theEuropeanPlasticsRecyclers–isthe

professionalrepresentativebodyofplasticsrecyclers

inEurope.EuPRpromotesplasticsmechanical

recyclingandanenvironmentthatencourages

profitableandsustainablebusiness.Theyprovidea

platformformembers,whorepresent85%ofEurope’s

recyclingcapacity,processingover5milliontonnesof

collectedplasticsperyear.

EPRO–theEuropeanAssociationofPlasticsRecycling

andRecoveryOrganisations–istheassociationof

thenationalorganisationsresponsiblefororganising

andpromotingrecyclingandrecoveryinEurope.

EPROprovidesauniqueforumforleadingEuropean

specialistsinplasticswastemanagementtoexchange

learnings,developintegratedplasticspackagingwaste

strategiesandsupporttechnologicaldevelopment.

PicturecourtesyofINEOS

4

Thisreporton2009production,demandandrecovery

isanannualpublicationbytheEuropeanplastics

manufacturersandtheirpartners.Thisisthe19th

editionofthisreport.

Theaimistoprovidedefinitivefactsabouttheplastics

market;fromdevelopmentandproduction,through

theirmanyuses,totheadvancesmadeinrecovering

plasticsattheendoftheirlife.

Dataiscollectedbyapartnershipinvolving

PlasticsEurope,EuPC(theEuropeanPlastics

Converters),EuPR(theEuropeanPlasticsRecyclers)

andEPRO(theEuropeanAssociationofPlastics

RecyclingandRecoveryOrganisations).

PlasticsEurope’sMarketResearchandStatisticsGroup

(PEMRG)providedinputontheproductionofand

demandforplasticsrawmaterials.ConsulticMarketing

&IndustrieberatungGmbHhelpedassesswaste

generationandrecoverydata.

Allfiguresandgraphsinthisreportshowdatafor

EU27+NorwayandSwitzerland–referredtoasEurope.

Anyothergroupofcountriesisspecificallymentioned.

Officialstatisticshavebeenusedforrecoveryand

tradedata,whereavailable,fromEuropeanornational

authoritiesandwastemanagementorganisations.

Researchorexpertisefromconsultantshasbeenused

tocompleteanygaps.

Figurescannotalwaysbedirectlycomparedto

previousyearsduetochangesintheestimatesof

bothmarketdemandandthewastegenerated.Some

estimatesfrompreviousyearshavebeenrevisedin

ordertotrackprogress,e.g.foruseandrecoveryof

plasticsacrossEuropeinthepastdecade.

Structure of the report

5

Navigating the crisis

Theglobalfinancialcrisiscausedunprecedented

difficultiesformanyandtheglobalplasticsindustry

wasnoexception.2009continuedtobeachallenging

year.Demandslowlycamebackbutfromaverylow

levelandataveryslowpace.

Withconsumerspendingmuchreducedresultinginlow

demandincustomerindustriessuchasautomotive,

constructionandelectronics–salesformanyplastics

companieswasverylowinthebeginningof2009.This

trendwasseenacrosstheplasticindustry–producers,

convertersandmachinemanufacturers.

Costefficiencyandrestructuringprogramscontinued

in2009tohelpcopewiththeeconomicdifficulties.

2009 Performance quarterly highlights

• Theglobalpolymerindustryshowedaweak

performanceinthefirstquarter.Therewasalarge

yearonyearsalesdeclinedrivenbyextremelylow

volumesandlowsellingprices.Globaldemand

improvedslightlyinJanuarythroughMarchfrom

verylowlevelsforthefirsttimeafterthecollapse

early2008.

• Globalplasticsdemandshowedfirstsignsof

stabilisationatlowlevelsinthesecondquarter.

• Thisdemandcontinuedintothethirdquarterwith

encouragingsignsforthefuture.

• Fourthquarter2009:onceagainbetterthanthird

quarter,butmainlydrivenbyAsia.

2009 Performance summary

• Globalplasticsproductionfellbackfrom245million

tonnesin2008to230milliontonnesfor2009asa

consequenceofthecontinuedeconomicslowdown.

• Europeproduced55milliontonnesandremaineda

majorregioncontributing24%oftheglobaltotal.

• Plasticslongtermgrowthisexpectedtobearound

4%globally,higherthanglobalGDPgrowth.

Averageconsumptionissignificantlybelowthe

levelof‘mature’industrialregionssothereisroom

forfuturegrowth.

• DemandfromEuropeanconvertersfellback7.2%

to45milliontonnesin2009.Volumeshareofall

countriesremainedlargelyunchanged.

• Polyethylene(PE-LD,PE-HD,PE-LLD)and

polypropylene(PP)accountforaround50%of

demandwithpolyvinylchloride(PVC)beingthe

thirdlargestpolymerat11%.

• Packagingisthelargestendusemarketsegment

with40.1%share.Thisisfollowedbybuildingand

construction(20.4%)andAutomotive(7.0%).

• SevenoftheEUMemberStatesplusNorway

andSwitzerlandrecovermorethan84%oftheir

usedplastics.

• TheEUMemberStatesplusNorwayand

Switzerlandtreated24.3milliontonnesofpost

consumerwastein2009.Thisresultsinanoverall

recoveryratefrompost-consumerplasticwasteof

54%,up2.7percentagepointscomparedto2008.

Themechanicalrecyclingrateup1.2percentage

pointto22.2%andtheenergyrecoveryrateisup

by1.5percentagepointsto31.5%andlandfillrate

isdownby2.7percentagepointsto45.8%.

66

1 Industry overviewOur contribution to wealth and life

Plastics enable us to produce more with less

PicturecourtesyofEVONIK

7

Plastics – providing a safe and sustainable life

Plastics meet the growing needs of society

Plasticsareacrucialpartof21stcenturylife.Notonly

dotheyprovideuswithuseful,lightweightanddurable

products,buttheyplayakeyroleinthesustainable

developmentofourworld.

Plasticsenabletheeco-efficientmanufactureof

productsincludingpackagingandelectronicdevices.

Lighterplasticcomponentsenablesafetyandresource

efficiencysolutionsforcarsandaircraft.Andplastics

helptoinsulatebuildingsandsavelivesinhealthcare

applications.

Plastics have a positive effect on climate protection

12%to15%ofamoderncarismadeofplastictohelp

toreduceweight,savefuelandreduceemissions.

Plasticcomponentsimpactfuelefficiencysaving

approximately2.5litresoffuelperkgused(equivalent

to6kgofCO2emissions)overthelifetimeofthevehicle.

Highperformanceplasticcompositesinthetoday’s

aircraftsimilarlyreduceweightandfuelconsumption.

Lightweightplasticpackagingreducestheweightof

transportedgoodsandtheamountofwastecreated

–bothofwhichreducegreenhousegasemissions.If

allplasticsusedinpackagingweresubstitutedwith

alternativematerialsitwouldbeequivalenttoadding

another25millioncarstoEuropeanroads.

Nearly40%ofallenergyconsumedisusedinbuildings.

Plasticinsulationhelpsourhomestostaywarmorcool

inasustainable,eco-efficientway.

Plasticsenablethebladesinwindturbinestobelonger

and,therefore,moreeffective.Plasticcomponentsin

solarpanelsincreasetheirefficiencyandmakethem

moreaffordable.

Paradoxically, the more plastics we use, the less

resources we need

ResultsfromPlasticsEurope’sreportfromDenkstattAG

(Theimpactofplasticsonlife-cycleenergyconsumption

andgreenhousegasemissionsinEurope,June2010),

confirmthatwithoutplasticpackagingitisestimated

thatthetonnageofalternativepackagingwould

increasebyafactorofalmostfour.Greenhousegas

emissionswouldriseby61%andenergyconsumption

by57%.

Plasticpackagingprotectsfoodasittravelsfrom

farmstosupermarketsandthenintoourkitchens.

Inthedevelopingworld,50%offoodiswasted

duringthisjourneywhilstonly2-3%getswastedin

Europe.Atthesupermarket,lossesofunpackedfruit

andvegetablesare26%higherthanforpre-packed

produce.1.5gofplasticfilmcanextendacucumber’s

shelflifefrom3to14days.10gofmultilayerfilm

formeatextendsshelflifefromafewdaystoovera

week.TheamountofCO2usedtoproduceasingle

portionofmeatisalmost100timesmorethanthat

usedtoproducethemultilayerfilmusedtopackage

themeat.

Theinnovativeuseofplasticinmodernwashingmachine

drumsreduceswaterandenergyconsumptionby

40-50%comparedtooldermodels.Plasticpipesensure

efficient,safeandleakfreetransportationofdrinking

waterandsewage,avoidingwasteorcontamination,

andreducestheenergyrequiredforpumping.

Plastics protect us and can help save our lives.

Carairbags,motorcyclists’helmetsandprotective

clothingaremadeofplastics.Firefightersrelyon

flexibleplasticclothingtoprotectagainsthigh

temperaturesandplasticequipmentprovideslife-

savingventilation.

Plasticpackagingprotectsourfoodanddrinkfrom

contamination.Plasticflooringandfurnitureareeasy

toclean,preventingthespreadofgermsandbacteria.

Inhealthcare,plasticsareusedinavarietyofways:for

bloodpouchesandtubing,artificiallimbsandjoints,

contactlensesandartificialcorneas,absorbablesutures,

splintsandscrewsthathealfractures.Newinnovations

willseenanoparticles/membranepermeabilitycarrying

medicinesdirectlytodamagedcellsandmicro-spirals

willcombatthesymptomsofcoronarydisease.

‘ Plastics protect the climate and enable resource efficiency’

8

The plastics industry plays an important role in our 21st century economy

Plasticsareaglobalsuccessstory.Theindustryhas

growncontinuouslyforover50years.Production

increasedfrom1.5milliontonnesin1950to230million

tonnesin2009.Thisgrowthisaround9%ayear

onaverage.

Thisannualgrowthwas,however,hithardbytheglobal

economiccrisis.Plasticsmanufacturerswitnesseda

drasticdecreaseindemandinparticularinEuropeand

thisbottomedoutatthebeginningof2009.

Withtheslowrecoveryrateitwillstilltakeseveralyears

fortheplasticsmanufacturingindustrytoreachthepeaks

ofpreviousyears.

Inthelongterm,theplasticssuccessstoryisexpected

tocontinueasplasticshavefarfromtappedall

substitutionpotentialwhichcomesontopofGDP

growth.Globalpercapitademandisgrowingata

longtermtrendof4%.Despitehighgrowthrates,

percapitaconsumptioninAsiaandCentralEurope

issignificantlybelowthelevelsofmatureindustrial

regions.Matureindustrialregionsarealsoexpected

toseegrowthratesslightlyaboveGDP.Thusthereis

roomforfurthergrowth.

Plastics saving lives

9

Plastics production

Figure2.WorldPlasticsProduction2009 Source:PlasticsEuropeMarketResearchGroup(PEMRG)

2009: 230

2009: 55

1985: 25

2002: 200

1989: 100

1976: 50

1950: 1,5

300

250

200

150

100

50

1950 1960 1970 1980 1990 2000 2010

Mtonne

year

World Europe

Figure1.WorldPlasticsProduction1950-2009 Source:PlasticsEuropeMarketResearchGroup(PEMRG)

Germany7.5%

Spain1.5%

UK1.5%

Italy 2.0%

France 3.0%

Benelux 4.5%

NAFTA23.0%

Latin America4.0%

Japan5.5%

China15.0%

Rest of Asia16.5%

Other EU 27+N, CH 4.0%

CIS 3.0%

Middle East, Africa8.0%

Europe (WE + CE) 24.0%, 55 Mtonne

230 Mtonne

AustriaBelgium & Lux.

BulgariaCyprus

Czech RepublicDenmark

EstoniaFinlandFrance

GermanyGreece

HungaryIreland

ItalyLatvia

LithuaniaMalta

NetherlandsPoland

PortugalRomaniaSlovakiaSlovenia

SpainSweden

UKNorway

Switzerland

1000 2000 3000 4000 5000 6000 7000

k tonnes

8000 9000 10000 11000 12000

939

2099

343

13

975

484

109

497

4541

10730

716

755

240

7042

135

182

13

1659

2481

787

571

366

219

3769

800

3578

213

789

2009 2008 2007

Figure3.EuropePlasticsDemandbyCountries(kt) Source:PlasticsEuropeMarketResearchGroup(PEMRG)

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Packaging

Building & Construction

Automotive

Electrical and Electronic equipment

Others

PE-LD,PE-LLD

PE-HD PP PS PS-E PVC ABS,SAN

PMMA PA PET Other Thermo-plastics

PUR

40.1%

20.4%

7.0%

5.6%

26.9%

Total: 45.0 Mtonne

The different application sectors

DemandfromEuropeanconvertersfellback7.2%from

2008to45milliontonnesin2009.Themarketshareof

enduseapplicationsremainedstablewithpackaging

thelargestsegmentrepresenting40.1%ofoverall

demand.ThisisfollowedbyBuildingandConstruction

(20.4%),Automotive(7%)andElectricalandElectronic

equipment(5.6%).Othersincludedifferentsmall

segmentslikesport,leisure,agriculture,machinery

engineeringetc.

Figure5.EuropePlasticsDemandbySegments2009 Source:PlasticsEuropeMarketResearchGroup(PEMRG)

Plastics applications

Packaging 40.1%

Building & Construction 20.4%

Automotive 7.0%

E&E 5.6%

Others 26.9%

45.0Mtonne

Figure4.EuropePlasticsDemandbySegments2009 Source:PlasticsEuropeMarketResearchGroup(PEMRG)

11

PUROther ETP

PCPA

PMMAABS, SAN

PETPVC

PS-EPSPP

PE-HDPE-LD, PE-LLD

Others

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000

2009 2008 2007

The different types of plastics

Therearearound20distinctgroupsofplastics,each

withnumerousgradesavailabletohelpdeliverspecific

propertiesforeachdifferentapplication.Therearefive

high-volumeplasticsfamilies;polyethylene,including

lowdensity(PE-LD),linearlowdensity(PE-LLD)and

highdensity(PE-HD)),polypropylene(PP),polyvinyl

chloride(PVC),polystyrene(solidPSandexpandablePS)

andpolyethyleneterephthalate(PET).Together,thebig

fiveaccountforaround75%ofallEuropeanplastics

demand.Themostusedresintypesarepolyolefins

(PE-LD,PE-HD,PE-LLDandPP)whichaccountfor

around50%ofallplasticsdemand.PVCisthethird

largestresintypeat11%.

Figure7.EuropePlasticsDemandbyResinTypes2009 Source:PlasticsEuropeMarketResearchGroup(PEMRG)

PE-LD, PE-LLD 17%

PE-HD 12%

PP 19%PS, PS-E 8%

PET 8%

PUR 7%

Others 18%

PVC 11%

45.0Mtonne

Figure6.EuropePlasticsDemandbyResinTypes2009 Source:PlasticsEuropeMarketResearchGroup(PEMRG)

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Global imports and exports

TheEuropeanUnionwastraditionallyanimportantnet

exporterofplasticproducts(plasticsandconverted

products).Thisexportrategrewbyover100%between

2000and2009reachingahighof€ 13billion.

Forplasticsmaterialsthebiggestexportmarkets

remainsChina(inclHongkong),TurkeyandRussia.

ForconvertedproductsEUexportsprimarilygoto

threecountries;USA(12.2%),Russia(11.6%)and

China(5.4%).Themainproductsexportedareplastic

plates,sheets,films,foils,tapesandstrips.This

represents36%ofallEUplasticexports.

However,since2008,thissituationhaschanged.

Fuelledbyaneconomicboom,Chinahasbecomea

significantexporterofplasticproducts,accounting

for33%ofallglobalexportsin2009.Additionally,

only2%ofthetotalexportedplasticproductsare

convertedproducts.

ThissituationmustbemonitoredcloselybyEU

institutionsifEuropeistoremainaplasticsexporter.

Exports for recycling

Aswithallmaterials,onceplasticsaresortedand

preparedreadyforrecyclingtheyareavailablefor

therecyclingmarket.Thismarkethas,aswithother

recycledrawmaterial,developedintoaglobalmarket.

Asignificantamountofsecondaryrawmaterialsare

recycledwithinEurope.Thisisduetoawelldeveloped

recyclingindustryandthefactthatmanyrecyclates

areusedintheproductionofnewproducts.Agood

exampleistheplasticbottle.Automatedprocesses

duringsortingandrecyclingandahighdemandfor

bottleuserstoincorporaterecycledcontentinbottle

manufacturing,meansthatmostofEurope’sbottles

arerecycledwithinEurope.

RecyclinginEuropepreventstheexportofvaluable

secondaryresourcesandstimulatesthelocal

recyclingindustry.However,wherealabourintensive

recyclingprocessisnecessary,muchplasticisstill

soldtorecyclersinAsia,particularlyChina.The

demandforplasticishighandduring2008China

imported7.07milliontonnesofusedplasticfromall

overtheworld.

Theplasticindustryisfullyawareoftheenvironmental,

economicandsocialresponsibilitiesassociatedwith

therecyclingofplastics,bothinEuropeandoverseas.

AllrecyclingpartnersoutsidetheEUmustfulfillthe

necessarylegalqualitystandardstoensurethat

recyclingconditionsare“broadlyequivalent”tothose

appliedinEurope.

6.0

5.0

4.0

3.0

2.0

1.0

2003 2004 2005 2006 2007 2008 2009 2010

Mtonne

year

5.5

4.5

3.5

2.5

1.5

0.5

EU27 Total Exports (Intra + Extra EU)

EU27 Total Imports (Intra + Extra EU)

EU27 Extra Exports (Extra EU)

EU27 Extra Imports (Extra EU)

Figure8.TrendsinEU27:TradewithPrimaryPlastics, trendcycle Source:PlasticsEuropeMarketResearchGroup(PEMRG)

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1.2

1.0

0.8

0.6

0.4

0.2

2003 2004 2005 2006 2007 2008 2009 2010

Mtonne (+ Surplus, – Deficit)

year

1.1

0.9

0.7

0.5

0.3

0.1

Primary Plastics Trade Balance (Extra EU)

Plastics Products Trade Balance (Extra EU)

1.2

1.0

0.8

0.6

0.4

0.2

2003 2004 2005 2006 2007 2008 2009 2010

Mtonne

year

1.1

0.9

0.7

0.5

0.3

0.1

EU27 Total Exports (Intra + Extra EU)

EU27 Total Imports (Intra + Extra EU)

EU27 Extra Exports (Extra EU)

EU27 Extra Imports (Extra EU)

Figure9.TrendsinEU27:TradewithPlasticsProducts, trendcycle Source:PlasticsEuropeMarketResearchGroup(PEMRG)

Figure10.EU27PlasticsIndustry:TradeBalancewithNon-MemberCountries,trendcycleSource:PlasticsEuropeMarketResearchGroup(PEMRG)

14

2

End-of-lifeIs there life after?

Plastics too valuable to throw away

15

The four R’s – Plastics’ significant contribution to the sustainable use of resources

Reduce

PlasticsreduceenergyuseandCO2emissions.

IfalloftheplasticusedinEuropeeachyearwere

substitutedwithamixofalternativematerialsthen

anadditional50milliontonnesofcrudeoilwould

berequiredannually.Usingplasticsinsteadofother

materialseffectivelyreducestheamountofCO2

producedinEuropebysome120milliontonneseach

year.Thisamountsto38%oftheEU15Kyototarget

for2000-2012.

Plasticsalsoreducewaste.Acrosstheirlife-cycle,

plasticsconsumelessandrequirelessrawmaterials

comparedwithothermaterials.Productspackaged

withplastics,fromfoodanddrinktocomputersand

TVs,lastlongerandarelesslikelytobedamaged.

Reuse

Plasticsarereusedinmanywaysfromsoftdrinkbottles

tosupermarketcarrierbags.Transportanddisplaytrays

areanotherexampleofreusedplastics,providinga

hygienic,robustandcost-effectivewayoftransporting

freshfoodfromretailer’sdepotstotheirshops.

Recycle

Plasticsrecyclingtonnagehasbeenincreasingannually

byapproximately11%peryearoverthepast10years.

In2009thisgrowthfellbacktojust3.1%onthebackof

theeconomiccrisis.

Itisnotonlybottlesandindustrialfilmpackaging

whichdrivethegrowth.Initiatives,whichinclude

thePVCindustry’sRecovinylsystem(coveringpipes,

windowframes,roofingmembranesandflooring),

andmixedpackagingplasticsrecycling,arealso

contributingtotheincreaseofplasticsrecycling.

Thisimportantdevelopmentmustcontinue.Thefull

potentialofexistingrecyclingstreamsmustberealised

andneweco-efficientstreamsdeveloped.

Recover

Therewillalwaysbeapartofend-of-lifeplasticsthat

isonlyeco-efficienttorecoverthroughanenergy-from-

wasteplantorprocessintoafuelthatcanbeusedas

anenergyresourcebyindustry.Withasimilarcalorific

valuetofueloil,plasticscanreadilybeusedasa

substituteforprimaryfossilfuels.

Plasticsaresimplytoovaluabletothrowaway.

Our vision

Ourvisionisforaforwardlookingresourcemanagement

approachthat:

• Takesintoconsiderationtheoveralllifecycleimpact;

• Minimisesthedisposalofvaluableplasticsinlandfill;

• Usesamixofrecoveryoptionsforthebest

environmentalandeconomicresults–inevery

situation;

• Ensuresthatthetreatmentandrecoveryofwaste

meetsdefinedenvironmentalstandards.

StylishfashionrecycledfromdurableflexiblePVC

16

Construction20%

Packaging40%

Expo

rt

Impo

rt

Others27%

E/E6%

Automotive7%

Expo

rt

Impo

rt

Expo

rt

40% short service life and 60% long

Converterdemand of

EU27+N/CH45.0 Mtonne

Consumerdemand

PC Waste24.3 Mtonne

46% Disposal 11.2 Mtonne

Recovery13.1 Mtonne

Recycling Energyrecovery

54.0%

5.5 Mtonne22.5 %

7.6 Mtonne31.5%

Less and less used plastic is going to landfill each year

Plastics, value chain during its lifecycle

Consumptionofplasticshasbeensteadilygrowingover

thepastdecadewithaconsequent3%increaseinpost

consumerend-of-lifeplasticwaste.However,landfill

amountsarenotinfactincreasing,asplasticend-of-life

managementimprovesyearly.For2009:

• Total2009plasticproductioninEuropewas

55milliontonnes,adecreaseof8.3%over2008

• Theconverter/processingindustrydemandwas

45milliontonnes,a7.2%decrease

• Postconsumerwastewas24.3milliontonnes,a

decreaseof2.6%over2008.Ofthis,11.2million

tonnesweredisposedofand13.1milliontonnes

wererecovered.

• Mechanicalrecyclingquantityincreasedby3.1%

becauseofstrongeractivitiesofsomepackaging

collectingandrecyclingsystemsaswellasthrough

strongerexportsoutsideofEuropeforrecycling

purposes.

• Energyrecoveryquantityincreased2.2%mainly

becauseofstrongerusageofpostconsumerplastic

wasteasalternativefuelinspecialpowerplants

andcementkilns.

• Overallthisrepresentsanincreaseof2.5%

intotalrecoveredquantityover2008.

Thediagrambelow(figure11)showsthelifecycleof

plastics–fromconverterdemandtofinallyrecovery

anddisposal.

Asthedatabelowhighlightstheconverterdemand

is45milliontonnes,butonlylittlemorethanhalfof

thiscurrentlyendsupeachyearaswaste(24.4million

tonnes).2009wasthefirstyearwhenthegenerationof

plasticswastefellfromthepreviousyear.Thedropwas

smallerthanthereductioninplasticsdemandat2%.

Figure11. Recoveryreached54%in2009–andcontinuestoincrease(EU27+NO/CH2009)

The27%Othersinfigure11referstofurniture,leisure,sportandmedicalapplications.

17

Progress towards capturing the full value of used plastic

Thereisnorightorwrongwaytorecapturevalueand

nosingleroutetoachievingthis.End-of-lifewaste

managementsolutionsvaryfromcountrytocountry,

dependingontheircircumstances,strategyand

availabletechnologies.Formanycountriestherewill

alsobemorethanonesolutioninplaceasconditions

varyfromurbantoruralareas.

Partofthesolutionhastobeanacceptancebysociety

touseresourcesefficientlyandthatvaluablematerials

shouldnotbeallowedtogotolandfill.Itisno

coincidencethatthetopnineperformingcountriesin

figure12allhavetightrestrictionsonlandfilling.Such

restrictionswillcreatestrongdriverstoincreaseboth

recyclingandenergyrecoverywhichhastakenoverall

recoveryratesabove80%.

Countrieswithahighrateofdiversionofvaluablepost-

consumerwastefromlandfillcombineahighrecycling

andenergyrecoveryperformance.Astrategywhich

includesenergyrecoveryis,therefore,notcontradictory

toachievinggoodrecyclingresults.Post-consumerplastic

wasteisbothsuitableasalternativefuelinspecialpower

plantsorcementkilnsandintraditionalEfW(Energy

fromWaste)plantsusingmunicipalsolidwaste.

Thegraphalsoshowsthatwhilstrecyclingperformance

isinmostcountriesbetween15and30%,theutilisation

ofenergyrecoveryvariesbetween0and75%.Countries

whichcurrentlylandfillvaluableend-of-lifematerial

haveanopportunitytoreducetheclimateimpact,

addresstheirenergydeficitanduseresourcesmore

efficientlythroughquicklyexpandingtheirenergyfrom

wastenetwork.

Theprogressincapturingthevaluefromplasticswaste

is,onaverage,slow.Therecoveryrateincreaseis

approximately+2percentagepointperyear.ManyEU

memberstatesneedtomakegreaterefforts,tobring

theirrecoveryrateto80%andmoreby2020.

Figure12.TotalRecoveryRatiobyCountry2009

(referredtoPost-ConsumerPlasticWaste)

SwitzerlandGermanyDenmark

SwedenAustria

BelgiumNetherlands

NorwayLuxembourg

FranceSlovakia

ItalyCzechiaFinland

HungaryEstonia

SpainPortugal

IrelandPoland

UKSlovenia

LatviaRomania

LithuaniaBulgaria

GreeceCyprus

Malta

20% 40% 60% 80% 100%

Recycling rateEnergy recovery rate

18

Award for the best recycled product

Consumersareoftenunawarethatthehigh-tech

productstheybuyconsistofasignificantamount

ofrecycledplasticwhichhassimilarmechanical

propertiesasvirginmaterial.

EPROintroducedtheinaugural‘BestRecycledProduct

Award’in2009,receivingover70entriesfromarange

ofsectorsacross13countries.

Theawardispresentedforproductsmadefromatleast

50%recycledplasticandaimstohighlighttheuseof

recyclatesinopen-loopapplications(i.e.thosewhich

userecycledplasticinadifferentwaytohowitwas

initiallyused).Additionally,theawardwasdesigned

tostimulatetheuseandqualityofrecyclatestohelp

encourageplasticsrecycling.

Aneight-strongjudgingpanelfromacrossEurope

selectedfourproductsforthetopthreeprizes.

Thecompetitionwasagreatsuccessandisbeing

runagainduring2010(inco-operationwithEuPR

andPlasticsEurope).Formoreinformationvisit

http://bestproduct.epro-plasticsrecycling.org/

FirstprizewenttoTeam-TexofFranceforaninnovative

child’scarseat.Thischaircontainsmorethan50%

recycledusedpolypropyleneandpolyethylenehigh

density,whilemaintainingoptimalsafetyresults,as

provenduringcrashtests.

SecondplacewasawardedtoPilotofFranceforits

“Bottle-to-Pen”(B2P)pen,thehousingofwhichis

madefromrecycledbottlematerial.

ThirdplacewasjointlyawardedtoLinpacPackaging’s

RfreshtraysforfoodandTheNobodyChair,designed

byKomplotinDenmarkandproducedinSwedenfrom

sourcematerial(recycledfromplasticbottles)by

WellmanInternational.

19

Tale of 3 countries with high plastics packaging recycling rates

ThethreeEUMemberStatesBelgium,Germanyand

Swedenallachievehighrecyclingratesforplastics

packagingthroughdifferentsystems.

Howevertherearealsosomecommonfeatures:

• Theyhaveinvestedmorethanotherstoinform,

motivateandstimulaterecycling.

• Theystartedearlyandhavealluniformnational

systemsforcollectionofplasticpackaging

(e.g.“bluebags”inBelgium).

• Theirnationallegislationdiscourageslandfilland

promotesrecyclingandenergyrecovery.

When comparing the 3 countries there are some

important differences.

Concerninghouseholdpackaging,Belgium

concentratesonbottlesonlyandcollectsplastics

bottles,metalcansandbeveragecartonsinthesame

bluebaginauniform,national,kerbsidescheme.

Germanycollectsallplasticspackagingfromhouseholds

includingbottles,rigidpackagingandfilmsinmainly

kerbsidecollection.Swedenusesbringstationsfor

allplasticspackagingandsomekerbsidecollection

forhouseholds.

WhilstGermanyhasninedifferent“greendot

schemes”,Belgiumonlyusesonenationalscheme

forhouseholdpackaging.InSwedenandGermany

newcompetingsystemsarechallengingtheoriginal

nationalschemeforallpackagingmaterials.

InSweden,thecommercialfilmstreamhasnonational

collectionschemeandnogreendotfeeasitisfully

self-sufficientandstillreacheshighrecyclingrates.

InBelgium,VAL-I-PACisthesystemforindustrial

packaging,withspecificrecyclingincentivesforthose

unpackingtoincreasetherecyclingofindustrialplastic

packagingwaste.

InGermanypackersandfillerscanadhereforinstance

toasystemthatallowstheirclientstoreturnthe

plasticpackagingfreeofchargetoacollectionpoint.

Thecollectedplasticpackagingfromhouseholdsis

transportedtoplasticsrecoveryfacilities(PRF)in

SwedenandGermanydesignedtodealwithamixed

plasticsstream.InBelgiumthesortingtakesplacein

amaterialrecoveryfacility(MRF)designedtosortthe

componentsofthebluebag.

Dependingonthematerialwhichiscollected,and

theinfrastructureofthesortingcentres,each

organisationhasitsownmixofsecondaryraw

materialswhicharesold.

Otherorganisationssellthematerialbytenderingto

recyclersandinthiswaytakeanactiverolewithinthe

market.Thisisthecaseforhouseholdpackagingin

somecountries.Athirdmodelusedinmanycountries

isbasedonagreementsandfinancialsupport,without

beinginvolvedasabuyerorseller.

Fromtheabovewecanseethathowtocollect,whatto

collectandhowtorefinethecollectedstreamisvery

differentinthethreecountries–andstilltheyallachieve

between40and44%recyclingrate.Theconclusion

isthereforethatthereis“notonesolutionfitsall”.

Thewinningformulaistodevelopasystemtailored

tothenationallegislation,thepackagingmixpresent

andthebusinessculture;combinedwithajoinedup

infrastructureofcollection,sortingandreprocessingand

thoroughandrepetitivecommunicationtocitizens.

20

EU Member States embark on implementation

strategies for the revised Waste Framework Directive

WiththerevisedWasteFrameworkDirectivedue

tocomeintoforceon12December2010,EU

MemberStatesarebusyplanninghowtodeliverthe

requirementssetoutinthedirective.

Itisclearthatthecollectionmethodandthechoice

ofandexpansionofinfra-structureforsortingand

reprocessingwillbecriticalfortherequirementsto

beachieved.

Collectioncanbebasedononebagforeverything

orseparatedstreamsfordifferentmaterials.The

WasteFrameworkDirectivesetsoutapreferencefor

separatecollectionbutothermeanscanbechosen

ifitistechnically,economicallyandenvironmentally

practicabletoachievethenecessaryqualitystandards.

BasedontheearlierexamplefromBelgium,Swedenand

Germanyitisclearthatgoodresultscanbeachieved

withdifferentsystems.However,itisimportantthatthe

collection,sortingandreprocessingarecomplementary.

SowhataretheinfrastructureoptionsavailabletoEU

MemberStateswhentheyembarkontheirdiversionof

plasticsfromlandfillcrusade?

• Material Recovery Facility (MRF)isasorting

technologytraditionallyusedformetal,glassand

paperbutcanalsohandleplasticsifappropriately

designed.Thistechnologysortsrecyclatesintotheir

componentsforfurtherreprocessingelsewhere.An

MRFresidualstreamwilltypicallyleavenon-sorted

materialwhichiseitherusedforEnergyfromWaste

ordisposedofinlandfill.Theresidualplasticsin

suchstreamprovidesignificantpartofthecaloric

contentforwasteincinerationwithoutwhichfuel

willhavetobeadded.

• Autoclave (or Mechanical Heat Treatment)isan

alternativetechnologytotreatunsortedMunicipal

SolidWaste(MSW).IttreatsMSWwithsteam

underpressuretoproducematerialwhichcanbe

sortedintotypeandthendirectsittorecyclingor

recovery.Thisprocessleadstomoreplasticbeing

recoverablefromtheMSWbutrequiresfurther

reprocessingforuseasasecondaryrawmaterial.

• Plasticssortingisrequiredformixedplasticrich

streamssuchasseparatekerbsideorbringstation

collection.Therapidtechnologydevelopmentin

sortingplasticallowssmallerandmorepieces

ofaparticularplastic(e.g.PP,PSorPVC)tobe

sortedindividuallyfromamixedplasticstream.

Aplasticsrecoveryfacility(PRF)issuitabletofurther

refinetheplasticstreamfromanMRForanAutoclave.

Besidessortingplasticsintoseparatetypes,sorting

systemswillsometimesreprocessthematerialby

cleaningandhomogenisingthematerialsoitis

suitableasalternativefeedstocktovirginplastics.

Whilstsomecountries–likeGermany–havealready

asignificantPRFcapacity,otherMemberStatesrely

uponforeignprovidersofthisservice.

GenerallymorecapacityisneededacrosstheEU.

AswithanMRF,itisnotpossibleforallplasticsto

besortedintoseparatetypes.However,theresidual

streamisanexcellentinputforfeedstockrecycling

orpotentiallyusedforsolidrecoveredfuel(SRF).

• Mechanical Biological Treatment (MBT)isa

techniquetotreatMSWaftersortingouttargeted

recyclablesbydryingandpartiallyremovingthe

easilydegradablecomponents.Theoutputfrom

suchtechnologyisapproximatelyhalvedinweight,

dryandwithahighercalorificvaluethantheMSW

andcanbereprocessedintoSolidRecoveredFuel

(SRF).Significantamountsofdifficult-to-recycle

wastestreamsareturnedintothisspecifiedfuel

acrosstheEUifthequalitylimitscanbemet.

Itissuitableforco-combustionreplacingfossil

fuelincementproductionorforpowerandheat

generationaswellasbeingusedwithbiomass.

SRFhashugepotentialandplasticsplayakeyrole

becauseoftheirhighcalorificcontent.

21

Vinyl 2010

TheVoluntaryCommitmentoftheEuropeanPVC

industrywassignedin2000by;

• ECVM(theEuropeanCouncilofVinyl

Manufacturers)

• EuPC(theEuropeanPlasticsConverters)

• ESPA(theEuropeanStabiliserProducers

Association)

• ECPI(theEuropeanCouncilforPlasticisersand

Intermediates).

Itisa10-yearplantosustainablyimproveproduct

stewardshipacrossthelifecycleofPVCinEuropeand

isregisteredasaPartnershipwiththeSecretariatof

theUNCommissiononSustainableDevelopment.

Thevoluntarycommitment,whichismonitoredbyan

independentcommitteeincludingrepresentativesfrom

theEUParliament,theEUCommission,EuropeanTrade

UnionsandConsumerAssociations,includesspecific

targetsandinitiatives.Theseareaimedatminimisingthe

environmentalimpactofthePVCproduction,promoting

responsibleuseofadditives,supportingcollectionand

recyclingschemes,andencouragingsocialdialogue

betweenalloftheindustry’sstakeholders.

Despitegenerallydifficultmarketconditions,the

Vinyl2010partnershipmaintaineditsdetermination

topursueitssustainabilitytargetsandobjectives

in2009andhasbeenabletoreportthatitisstillon

tracktomeetthecommitmentssetoutinits10year

programme.

Thehighlightsofitsachievementsfor2009werethe

recyclingof190,324tonnesofpostconsumerPVC

(thankstotheongoingconsolidationofnational

collection/sortingschemesundertheindustryfunded

pan-EuropeanRecovinylsystem);andtheongoing

phase-outoflead-basedstabilisers,whichisnow

well-aheadofschedule.

Forfulldetailsvisitwww.vinyl2010.org.

2 litre house - leading the way in energy efficiency

PicturecourtesyofECVM

22

Mechanical recycling of plastics

Mechanicalrecyclingisthereprocessingofend-of-life

plasticsintoare-usablematerialthroughaphysical

ratherthanachemicalprocess.Physicalprocessing

essentiallydoesnotbreakdowntheoriginalpolymer

chainsandmoleculeswithintheoriginalmaterial.

Thematerialisabletobere-formedintousefulnew

productswhilstleavingthematerial’soriginalstructure

andpropertiesintact.

Mechanicalrecyclingtypicallycomprisestheseparation

ofpurefractionsofspecificpolymersintocommercially

saleable,readyforprocessing,plasticpelletsthatthe

convertingindustrycanusetomakenewproducts.

Thetreatmentprocessconsistsgenerallyofshredding

oldproductsdowntosmallpieces,separationunitsto

extractspecificsizesormaterialsfromthemainmaterial

flow(e.g.magneticdrumstoseparateferrousmetals

andsophisticatedsortingtechniques,likeinfra-red

scanning,todifferentiatebycolour);andmillsand

extruderstoconverttheseparatedplasticsfractionsinto

newmachine-readygranules.

Mechanicalrecyclingofproduction(“industrial”)

waste(off-cutsetc)hasdevelopedinparallelwith

thedevelopmentoftheplasticconvertingindustry.

Mechanicalrecyclingofpost-consumerwaste

(end-of-lifeproducts)beganinthe80sandtook

offinthe90s,spurredbylegislationmandating

minimumrecyclingratesofcertainwastestreams

(e.g.packaging),separatecollectionschemesand

progressinsortingtechnologies.

Thekeysuccessfactorsforeco-efficientmechanical

recyclingare:

• cleanandhomogeneouswastestreams;

• processesthatproducerecyclateofaqualitythat

canreplaceanequivalentweightofvirginresin;

• ensuringthatthemarketwillacceptproducts

containingrecyclate.

23

More effective catalysts drive development of feedstock recycling

Energy from Waste

Feedstockrecycling–amethodtoconvertthe

hydrocarbonchainintoshorterblockswhichcan

thenberebuiltintonewpolymers–hasbeenin

useforthepast25years.

Developedaftertheoilcrisisinthe1970s,thefirst

generationfeedstockrecyclingconvertedplasticrich

wastestreamssuchashouseholdpackaging,and

industrialplasticsintofuel.

Subsequentdevelopmentsincludedtheuseof

gasificationandthermalcrackingformixedplastics

andchemicaldepolymerisationtechnologyfor

specificpolymers.

Withits2020energyconservationandclimateprotection

goalstheEUtargetstoreduceEUgreenhousegas

emissionsbyatleast20%below1990levels.Thiswill

beachievedthrougha

1. 20%ofEUenergyconsumptioncomingfrom

renewableresources.

2. 20%reductioninprimaryenergyusecompared

withprojectedlevels.

Plasticswillcontributetotheoverallreductiongoalas

oneoftheleadingmaterialsduringusephaseinmost

allapplications.FurthermorewasteplasticsinMSW

canberecoveredinenergyfromwasteplants(EfW)and

plasticsinSRFcanberecoveredinindustrialproduction

plantssuchaspulpandpaper,cement,limeandbrick.

SignificantcontributiontoCO2reductionissecured.

BydivertingmixedMSWfromlandfill,whereit

otherwisewoulddecomposeandformmethaneand

CO2.Alsothroughreplacingfossilfuelslikecoalwith

SRF,considerableCO2reducingisbeingsecured.

Morerecentlytechnologydevelopingcompanieshave

focusedonfeedstockrecyclingbyusingcommercially

availablecatalystandprocessingtechnology.Thisrecent

initiativeisnotyetproveninlargescaleoperations.

Manylifecycleassessmentsshowthatfeedstock

recyclingfrommixedplasticwastehasatleastasgood

environmentalperformanceasmechanicalrecycling.

Thekeysuccessfactorwillbetoachievehighyield

andselectivityinpolymerconversiontoproducethe

rightrawmaterials.Higheroilpriceswillalsomake

feedstockrecyclingmoreattractive.

Thestrivingtoincreaseefficiencyhasbeenpromoted

throughseverallegislativeinitiativeslikethenewWaste

FrameworkDirectivewiththe60/65%minimum

energyrecoveryefficiencytarget.Theplasticsindustry

supportsallhighefficiencyenergyrecoveryoperations.

Toachieveenergyefficiencyabove80%ahigh

qualitySRFfuelisrequired.Plasticsisthekeycalorific

contentprovider.Suchfuelrequireshighqualityanda

standardizedspecificationisbeingprogressedinCEN.

24

3 Innovation

Plastics reduce the environmental

impact of transportation

Picturecourtesyof©Renaultcommunication/RENAULTDESIGN

25

Transportation

Car components

Innovativeusesofplasticsincarsincludereplacing

glassinheadlightlenses,bezelsandwindscreens

aswellasreplacingsteelforfenders,spoilersand

dashboards.Plasticcomponentsimpactfuelefficiency

savingapproximately2.5litresoffuelperkgused

(equivalentto6kgofCO2emissions)overthelifetime

ofthevehicle.

Car production efficiency

ThelatestSmartCar–SmartForTwo–benefitsfroma

pioneeringpolymer-basedcompound.

Thislatestinnovationofferssignificantadvantages

–improvingSmartCarproductionefficiency,vehicle

safety,environmentalperformance,runningcosts

andaesthetics.Ithasahighdimensionalstabilityand

materialtolerancewhichmakesthecar15%lighter

thanpreviously,thusloweringfuelconsumptionand

CO2emissions,transportationandvehiclecosts.

Additionally,onlyonelayerofpaintisrequiredand

asmootherfinishisachieved.Thismeanslowerpaint

repaircostfordrivers.

The 100% plastic car – no longer an imaginary concept

Automotivedesignersandengineershavelongdreamed

ofmakingacarthatissuper-efficient,safeandlight.

Nowitmightnotbetoolongbeforeanall-plasticcar

thatmeetsthesecriteriaismass-produced.

ThefirstplasticcarwasmadebyFordin1941.Using

plasticthatwas70%cellulose,thecarwaslight:

weighing30%lessthanitsmetalcounterparts.But

cheappost-warsteelandinexpensivegasolinemade

theseplasticcarsunattractive.

Whenonethinksofthestructureofanautomobile,

themetalthatmakesuptheframe,chassis,nuts

andbolts,rivetsandscrewscomestomind–

providingstability,formandsafetytothevehicle

anditsoccupants.However,plasticsareincreasingly

substitutingmetalsinautomanufacturetoday,and

meeting,ifnotsurpassing,thestability,formand

safetyrequirements.

Althoughhigh-endautomobilesincreasinglyuse

glassfibreandothernon-metals,theirframesare

stillmadeofmetal.Thechallengethattheplastics

industryhasiswiththechassiswhichtendstobethe

high-weightsectionofavehicle.However,thelastfew

yearshaveseensubstantialinvestmentsinresearch

intotheuseofcarbon-fibreautopartstargeting

chassisandbodyapplications.Whensuccessfully

adapted,thiswouldbeagreatleapforwardfor

automotiveengineering,andanothersteptowards

the100%plasticautomobile.

PicturecourtesyofBASF

26

Consumersarepreparedtospendmorewhenacar

comeswithaneco-friendlyorfuel-savinglabel.Some

luxuryautomobilemakershaverecentlyturnedto

carboncompositefibresforstructuralandinterior

bodyparts.However,thehighrawmaterialcostsof

carbonfibreisstillakeydeterminingfactor.Ifcost

werenotanissue,carscouldbemadecompletelyof

carbonfibre.Thecostofmetalstillremainsatenthof

thatofcarbonfibre,eventhoughcarbonfibrecosts

havedroppedten-foldinthelastdecade.Butallthat

issettochange…

Thedriveforinnovationandhigherfuelefficiency

requirementswillwithoutdoubtresultintheincreased

useofplasticsinautomobiles.Alreadymorethan50%

ofatypicalvehicle’svolumeiscomposedofplastics

andpolymercompositesandtheseaccountforonly

10%ofthetotalvehicleweight.

Butotherprogressivechangesaretakingplacein

theautomobileindustry.Forexample,fueleconomy

standardsaregettingstringent.A10%reductionin

vehicleweight(about100kilos),whichcanbeachieved

usinglightweightmaterialslikeplastic,resultsin

5%fuelsavingsor2.5litresperkgofplasticsused

overtheaveragelifetimeofavehicle.Also,theuse

ofpolycarbonatewindows,indevelopmentforover

10years,andnowreadyformass-adoption,canreduce

windowweightbyupto50%.

Anotherkeyadvantageofplasticisthatitismoulded

andnotstamped.Mouldscancreatecomplexshapes

thataredifficulttocreatewithstampedsteel,and

multiplepartscanbemouldedatthesametime.Today,

smaller,nichevehiclesareusingmouldedplasticparts

moreandmore.

Soontheautomotiveindustrywillacknowledge

andrecognizeplasticasthepreferredmaterialfor

production.Plasticwillnotonlymeet,butinmany

casesset,futureautomotiveperformanceand

sustainabilitystandards.

Plastics in aircraft

Weightiseverythinginaircraft–andbodyweightcan

besignificantlyreducedbyusingplasticcomposites.

Thenextgenerationofpassengeraircraftbenefits

fromplasticinnovations.22%ofthecomponentsin

theAirbusA380aremadefromplastics.Innewplanes

liketheAirbusA350(due2013)andtheBoeing787

Dreamlinerthisproportionofplasticusedinthe

constructionwillincreaseto50%.

Solar energy

Thefirstroundtheworldflightinasolarairplanehas

beenmadepossiblebytheinnovativeuseofplastics.

TheSolarImpulseproject,thebrainchildofBertrand

PiccardandAndréBorschberg,aimstodevelopthe

firstmannedflightaroundtheworldduringboththe

dayandnightpropelledwithonlysolarenergy.

Theprototypeairplanehasthewingspanofalarge

airliner(63.40meters)andtheweightofamidsizecar

(1,600kg).Over12,000solarcellscoveritssurface.

Theyrunfourelectricalenginesandstoretheenergy

foruseatnightin400kgoflithiumbatteries.

High-techpolymermaterialsusedontheplaneinclude

polyurethanerigidfoamsforpanelinginthecockpit

andengine,andextremelythinyetbreak-resistant

polycarbonatefilmsandsheetforthecockpitglazing.

Carbonnanotubeshelpincreasebatteryperformance,

improvestructuralcomponentsandreduceweight.

27

Electrical & Electronic equipment

Building and Construction

Plasticsplayapivotalroleinthedevelopmentand

progressoftechnologiessuchasOLED(organiclight

emittingdiode)displaysandlighting,organicsolar

cells,smartpackagingorconductivenanoinks.

Onecutting-edgeadvanceistheprintedelectronic

circuitboardforwhichtheplasticsindustrycontinues

developingitsnanomaterials.Thenanoinkisbasedon

carbonnanotubes(CNTs)andsilvernanoparticles.

TheCNTinkisspecificallytargetedattheprinted

electronicsmarket,offeringconductivityandgood

adhesiontoplasticfilmsforflexiblesubstrateswhich

wouldresultinelectronicsthatareeasier,cheaperand

simplertointegratethanever.

Oneoftheapplicationscouldbeasolarbagintegrated

withplasticandprintedcellstoharnessenergy

includingindoororatlowlightconditions.Theenergy

collectedwouldthenbetransferredtoabatteryto

chargeelectronicdevicessuchascameras,mobile

phonesore-readers.

Innovativeplasticinsulationforbuildingsprovides

greaterenergyefficiencyovertraditionalmaterials.

Plasticinsulationpanels,whichcanbeusedonwalls,

roofsandflooring,areeasytoinstall,comewithclimate

friendlyfoamingagentsandresultinareductionin

leakagefrombuildings.Theyalsomeanthatthinner

wallscanbeconstructedinbuildingsbecausethe

panelsinsulatemoreefficiently.Overthelifetimeof

abuilding,just1kgofplasticcansaveupto755kg

ofCO2emissions.

Plastic piping for water transport

Thelatestgenerationofplasticmaterialsenable

fastandeconomicalpipeinstallation.Thedurable

pipesarestrongenoughtobeinstalledinvery

demandingconditions,thusreducingtheoverall

infrastructurecosts.

Newgenerationplasticpipesoffermaximumprotection

againstsurfacedamageduringtransportandlaying,

thepointloadscausedbysharpedgestonesand

bedding,andthestressinthepipewallgeneratedby

externalloadssuchastrafficorearthsettlement.

28

Packaging

Reclosable packaging means responsible packaging

Moderninnovationsinplasticpackagingdesign

forfoodofferconsumersnumerousbenefits–from

conveniencetoreducingwasteandimprovinghygiene.

Cheeseboardpackagingenablesdifferenttypes

ofcheesetobeindividuallyportionedbutpacked

inonepack.Thepackagingconsistsofatraywith

separatecavitieswithasealedlid.Contourperforation

technologyonthepackagingmeansthatconsumers

caneitherpeelthelidopencompletelyorpushan

individualcavitytogetthepieceofcheesetheydesire.

Thishelpstokeepthefoodfreshandavoidwaste.

Newpackagingforslicedmeatenablesconsumersto

openandthenreclosepackagingwithanadhesiveflap.

Othermeatpackaginghastwocompartmentsontopof

eachotherseparatedbyaninterlayer.Thismeansone

compartmentcanbeopenedandconsumedwhilstthe

othercompartmentcanbeopenedlater,thuskeeping

thefoodfresherforlonger.

Innovativepackagingcanhelptoreduceproduct

weightandtheassociatedtransportandstorage

costs.Plasticscontainersforfruitandvegetablesare

easilystackable.AleadingUKsupermarketusesthese

containersinplaceoftraystoreducethepackaging

weightoftheirblueberriesby75%.Retailersare

alreadyusingheatsealedplasticpeelablelidsinplace

offcliponlidsontheirtraysofstrawberries,saving

tonnesofplasticperyear.

Otherinnovationsincludezipbagswithsolidbottoms

whichcanbere-sealed(thesereplaceglassjarsfor

teaandcoffee)andsidegussetpouchesforarange

offoods.Thesefoldflatbeforefilling,thusreducing

freightandstoragespaceandassociatedcosts,

anduse75%lessplasticthanrigidcontainers.Side

gussetpouchesalsoofferlongershelflifewithout

refrigeration.

PicturecourtesyofAmcor

29

Leisure and sport

Plastic football which changes colour

Arevolutionarynewfootball,currentlyindevelopment,

isbeingmadepossibleviatheuseofinnovative

syntheticplastics.

ThelightinsideCTRUSfootballchangescolourfrom

greentopurpleaccordingtowheretheballissituated

onthefootballpitch,assistingtherefereestomake

moreaccuratedecisions.

Theballhasaninternal‘skelle-core’andasynthetic

plasticouterskinmadeofelastomerswhichhelpsit

toemulatetraditionalinflatedpneumaticfootballsbut

withtheaddedadvantageofnotrequiringair.AGPS

chipsituatedinsidetheballcanbeprogrammedto

changecolouronceitcrossesthegoallineorgoesout

ofplay.Additionally,thechipcancalculateballspeed

orthepowerwithwhichtheballisstruck.

Healthcare

Plastic in healthcare

Plasticsarebeingincreasinglyusedinhealthcare

applications.Peoplearelivinglonger,buttheincidence

ofallergiesandepidemicvirusescontinuestorise.This

meansmorehygienicdisposablehealthcareproducts

arerequiredwhichreducetheriskofcontamination.

Plasticsareusedinmedicaldevices(e.g.tubing,blood

bags,syringesandinsulinpens)andpharmaceutical

anddiagnosticpackaging(e.g.bottlesandampoules

forintravenous(IV)sterileliquids,tubesandblister

packsfortablets).

Theyhaveanumberofadvantages.Theyare

transparent,haveahighchemicalresistance,areeasy

tosterilize,provideanexcellentbarriertowatervapour

andarenon-harmfulwhenincinerated.

Sensory wristwatch

Apolymerbasedwristwatchcurrentlyindevelopment

inGermanyisabletodetectmedicalproblemsbefore

theybecomeanemergency.Thediagnosticwatch

combinesseveralbiomarkersensorsintoonedevice

andcanmonitorthewearerforsignsofdehydrationor

fluctuationsinbloodsugarlevels.

Advancesinpolymerelectronicsandsensorsmean

thatthistypeof‘lab-on-a-chip’watchcould,infuture,

enablehighriskpatientstohaveaconstantstreamof

biofeedbackontheirhealth,helpingthemtoavoidlife-

threateningincidents.

30

Snapshot 2010

Theannualgrowthpatternoftheplasticsindustrywas

hithardbytheglobalcrisisearly2008,bottomedoutin

early2009andhassincebeenonaslowrecoverypath.

Afteratightmarketsituationinthesecondquarterof

2010therearesignsofastabilisationofthemarketfor

therestoftheyear.

Thebackgroundforthiscouldbe:

• Chinaisslowingdowntheirgrowth

• SeveralEUmemberstatesareontoughbudgetcut

backpolicieswhichwillreduceconsumption

ConsumptionbyEUplasticsconvertersisexpected

toincreaseby3-5%over2009leavingstillalongway

uptowheredemandwasbeforethecrisis.Thisis

drivenbothbyareturninconsumerconfidenceand

acontinuedsubstitutionofalternativematerialsby

plasticsinanumberofapplications.

WithChinaandtheMiddleEastbuildinghugeplastics

productioncapacityEuropeanplasticproducerswill

bothfaceincreasedcompetitionfromimportsinEurope

andonexportsmarkets.Alsotheconvertingindustry

faceshugepressurefromlowercostscountries.

ToremaincompetitivetheEuropeanplasticsindustry

needstofocusoncontinuousimprovementand

innovationalongthesupplychain.

TheEUlegislatorsalsoneedtofindthebalance

betweenontheonehandtheneedtoleadtheworld

insustainabledevelopmentandontheotherhand

toeconomicgrowthintheEUtosecurejobsand

socialwelfare.

Withconverterconsumptionofplasticsincreasingagain

wecanexpectthegenerationofusedpost-consumer

plasticstoincreaseby2-5%in2010over2009.

Recyclingisexpectedtocontinueincreasebutwith

stillasignificantpartofthequantitybeingexported

forreprocessingintheFarEast.Thefirsteffectsof

thissituationcanalreadybeseenontherecycling

markets.Asamatteroffact,duetoashortageof

availablematerialthefirstmonthsof2010haveshown

aconsiderablepriceincreaseofthecollectedplastics.

Alsoenergyrecoveryisexpectedtoincreaseonthe

backofactivitiesinanumberofMemberStates.

130

120

100

80

60

1991

Index (2005 = 100, Trend cycle)

year

1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

110

90

70

50

Plastics machinery

Manufacture of plastics products

Plastics in primary forms

Figure13. PlasticsindustryproductioninEU27Source:Eurostat/PlasticsEuropeMarketResearchGroup(PEMRG)

31

Glossary of terms

ABS Acrylonitrile-butadiene-styrene plasticCE Central EuropeCEN The European Committee for StandardisationCNTs Carbon nanotubesCO2 Carbon DioxideECPI European Council for Plasticisers and IntermediatesECVM European Council of Vinyl ManufacturersEfW Energy from WasteEPR Extended Producer Responsibility EU European UnionEuPC European Plastics ConvertersEuPR European Plastics RecyclersEPRO European Association of Plastics Recycling and Recovery OrganisationsESPA European Stabiliser Producers AssociationE&E Electrical & Electronic equipmentGDP Gross domestic productGPS Global Positioning SystemGPCA Gulf Petrochemicals and Chemicals AssociationIV IntravenousKg KilogrammeKt Kilo tonnesMBT Mechanical Biological TreatmentM tonne Million TonnesMRF Material Recovery FacilityMSW Municipal Solid WasteNGOs Non governmental organisationsOLED Organic light emitting diodePA PolyamidePE PolyethylenePE-HD Polyethylene, high densityPE-LD Polyethylene, low densityPE-LLD Polyethylene, linear low densityPEMRG PlasticsEurope Market Research GroupPET Polyethylene terephthalatePUR PolyurethanePMMA Polymethyl methacrylatePP PolypropylenePRF Plastics Recovery FacilitiesPS PolystyrenePS-E Polystyrene, expandablePVC Polyvinyl chlorideSAN Styrene-acrylonitrile plasticSMEs Small and medium sized enterprisesSRF Solid Recovered FuelTV TelevisionUK United KingdomUN United NationsWE Western EuropeWRAP The Waste & Resources Action Programme

2010

-09

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