Lucas, what are the teams at your institute researching?

Lucas: Our research is dedicated to the development of natural bioplastics and their processing. Recycling is also a focus topic for us - for biopolymers as well as for conventional plastics. We are also investigating options for planning environmentally friendly recycling design and drawing up greenhouse gas balances.

In order to make plastics more sustainable, solutions must be found to reduce the proportion of new raw material or virgin material. What options are there for this?

Lucas: On the one hand, residual materials from production processes or waste materials can be reused. On the other hand, the proportion of virgin materials can be reduced through the alternative use of bio-based or biodegradable plastics. Here you have to take a close look at how production takes place and what is the more sustainable method in each individual case. To be honest, however, we still have a long way to go before we can talk about a completely sustainable plastics industry. Anyway, the beginnings are there and are being driven forward at high speed in research and by some companies.

When you think about the reuse of old materials, you might think that there is easy potential to be found here, and at a reasonable price. After all, waste materials are being used. Is that the case or what are the challenges?

Lucas: Unfortunately, it's not that simple. Behind the recycling of waste materials are complex processes for taking back, cleaning and reprocessing the materials. These must be of a certain quality and must not impair the material properties, for example the durability or safety of a product. Companies have to invest additional resources in research and testing to adapt manufacturing processes and ensure that the product meets the same quality requirements despite a different material composition. In addition, good, recycled materials are rare and often more expensive than fossil-based virgin materials due to the effort involved.

Andreas, what role does the circular economy play at REHAU?

Andreas: For us, the circular economy is one of our key areas of activity. Continuously increasing the proportion of recycled material in our products is one of our most important goals. What many people don't even know: REHAU has had internal cycles since the 1950s. In order to save costs and conserve resources, old materials from production processes were collected, processed, and used for the manufacture of new products. As a result, we have many years of experience in processing and recycling production waste. At the same time, we have been working with partners for many years to close external cycles. In our REHAU Window Solutions division, more than 60 percent of the total production tonnage contains recyclate. This proportion of recycled material is up to 80 percent and is being continuously increased. Other examples include the first take-back concepts in our Building Solutions and Interior Solutions divisions.  

Are the challenges you mentioned also an issue at REHAU?

Andreas: Yes, indeed. The recycling market is highly competitive, very fragmented and non-transparent. Material with similar specifications is only available to a limited extent and demand is expected to increase further.

Dominic: Another challenge is quality: we manufacture technically and visually sophisticated products for which we need recycled material of an appropriate and consistent quality. Depending on the source, recycled material can be contaminated or have colour limitations, and the availability of high-quality material is limited.

Dominic, you are a central development unit within REHAU. What exactly are you working on?

Dominic: We are working on new approaches based on materials and technology to support other areas in the further development of their products. For us, the focus is on the added value for our customers and making a targeted contribution to technological innovations. I am part of the recycling specialization area. Our focus is on qualifying suitable recycling materials for use in existing or new products. We also look at new recycling technologies, from mechanical to chemical recycling, or evaluate the use of alternative, sustainable materials, for example in the form of bio-based raw materials. It is important that the recyclable design of products is considered from the outset.

How can this be taken into account?

Dominic: The circular economy begins even before the product exists, in the development phase. This is because the further stages in the life cycle along the value chain should already be considered here: Which material composites are necessary? How durable are the materials used? How can the abundance of different materials used be reduced?

Andreas: To take this into account, we at REHAU have developed so-called Circular Design Principles and a Circular Scorecard. These are concepts that break down various criteria and help us to consider step by step how the product and the supporting processes can be made more sustainable and circular.

How important is exchange and collaboration?

Dominic: We are always open to new ways of thinking. This requires internal cooperation, intensive discussions with customers and suppliers, but also an exchange with experts from the world of science, such as the Polymer Institute in Hof, Germany. In recycling in particular, a large network of partners along the value chain is extremely important to ensure the required and consistent quality of recycled materials and to close material cycles. We work every day to ensure that these connections grow even closer together.

Andreas: No matter what we are talking about in terms of sustainability, it can only be achieved together. This requires the right structures and an open culture both inside and outside the company to promote internal and external networking and the exchange of knowledge.

How do you think the future of the circular economy will develop in the polymer industry?

Andreas: We can see that the requirements in the form of regulations and standards will continue to increase. At the same time, public awareness is growing, and sustainable practices are increasingly being demanded. The players will have to work even more closely together to find joint solutions. The use of recycled materials is only an intermediate step. In the future, services to extend the useful life of products will become much more important.

Dominic: The increasing demand for recycled materials will promote innovation and investment in this area even more. From a technical perspective, existing recycling processes will continue to develop and alternative methods such as chemical recycling will become established. I also believe that sustainable product design will become even more important. Companies will have to think more about circularity issues from the outset and take on more responsibility in this regard.

Lucas: I think research into material alternatives and recycling will make great strides forward and there will be a widespread rethink in the industry. The use and possibilities of bioplastics and recycled materials will increase dramatically. The circular economy will no longer be a term that requires explanation, but the standard for driving forward the transformation to a more sustainable economy step by step.