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October 17, 2023 05:26 PM

Recycling moves from mainstream to faltering industry

Beatriz Santos
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    PN20231017p22 Erema-main_i.jpg

    The last edition of Fakuma, back in October 2021, was hailed as the show when recycling moved from niche to mainstream.

    The industry had started its recovery from the COVID-19 pandemic with sales books filling up quicker than in 2019. Regulations calling for recycled content and public pressure were highlighted as main factors driving demand on the show floor.

    In the meantime, high prices for virgin resin, which guide the price of recyclates, were allowing recycling companies the margins to further invest in new products and technologies.

    Fast forward to 2023 and recycled resin prices are under severe downward pressure because of persistent weak demand, competition from the falling cost of off-spec virgin plastics and cheaper imports from Asia. Recycled PET has been particularly affected.

    There are some recent signs of improvement, however. Virgin polymer prices registered strong price gains in September, and the situation might keep improving with crude oil costs soaring.

    Nevertheless, weakened European economies and stubbornly strong inflation rates continue to restrain end user demand. When inflation is high and consumers end up having less money to spend, they tend to restrain their spending to essentials — are they still willing to pay a premium for packaging with recycled content, for example?

    Sustainable Plastics caught up with the CEO of industry leader Erema Group, Manfred Hackl, to discuss how these circumstances are affecting the company. Compared with last year, the Austria-based manufacturer of machinery for plastic recycling is seeing percentage sales drops in the double digits.

    Plastics News/Caroline Seidel

    "The sales are not on the level of the last years. The intake is lower, especially in Europe, no discussion about that," Hackl said.

    "But we have other regions all over the world that we are still getting orders from. We are currently benefiting from two things. First, that we have a broad product portfolio, including recycling machines, filtration systems, high-tech components, and used and remanufactured machines. That broad customer base ensures higher stability, especially in these economically challenging times. And second, we benefit from the fact that we brought two energy-saving technologies onto the market last year that help our customers make significant savings in energy consumption and thus achieve greater profitability.

    "For example, with our EcoGentle technology, up to 12 percent energy savings can be achieved in special applications in PET recycling while maintaining the high recyclate quality. Given high energy prices, this is an increasingly important purchasing decision for recyclers," Hackl said.

    The dire situation is not exclusive to the plastic recycling sector. The general economic situation all over Europe means that people are reducing their consumption, be it in the construction, automotive or plastic sectors, Hackl commented.

    "Due to the fact that less material is used by the converter, recyclers are producing less material. On top of that, there's the high energy prices so it's really quite a tough time, especially for recyclates in the lower-quality end segment," he added.

    Not all is gloomy and gray, though. Erema is already seeing signs of recovery. "We see that we have already reached the bottom of the curve. We think [demand] will go up in the next months — how strong and how fast, one hears different rumors in the market," Hackl said.

    The main recovery indicators, according to Hackl, are the slight rise in prices of virgin polymers and recent forecasts indicating some economic growth in Europe for 2024. The latest figures for Austria predict a growth of 1.5 percent in 2024, compared with a 0.6 percent contraction in 2023.

    This slow recovery, however, won't be enough to repair the damages to the European Union's 2025 recycling targets, Hackl said.

    "I think it will be quite hard — and frankly unrealistic — to fulfill the targets for 2025. Very little investment in being done in Europe," Hackl said.

    Whilst the industry is faltering, Erema's CEO is positive it is not a dying one. Policy support from Brussels is needed to stimulate it, he said, as well as understanding that plastics are a tool to achieve climate neutrality.

    "[Supporting the plastic recycling industry] would build an economic incentive for Europe because we can export this technology; we can export this know-how and do businesses all over the world, which would be a gain for the economy in Europe. We also need to explain to the politicians that plastics are a solution for climate neutrality, because we need less energy than paper and glass. Without support for the industry, we end up producing more CO2 through other materials," he said.

    Industry body Plastics Recycling Europe has argued that enforcement mechanisms are needed to level the playing field between Europe and Asian countries exporting recycled polymers into the continent. It said Europe is using "nontransparent imports" from non-European countries to meet targets set by the Single Use Plastics Directive rather than supplying that demand with made-in-Europe recycled PET.

    Between 2021 and 2022, the main imports of PET came from India, China and Turkey, followed by Indonesia, Egypt and Vietnam — countries where energy and labor costs are significantly cheaper than in Europe.

    Erema's CEO echoed the sentiment by noting that Europe is the birthplace of the plastics recycling industry.

    Mixed Litter at Fakuma Trade Fair in Friedrichshafen Germany October 2023. Foto: Plastics News/Caroline Seidel

    "I think we have to keep in mind that the industry was born here. We have developed it — the products as well as the machinery. It would be a shame if we were to give up on this industry now. We have strong innovation power, but we also need the circumstances to help us put this power to use," he said.

    At Fakuma, Erema is doing its share of the task. It is announcing a new artificial intelligence-powered, self-learning software tool that automatizes the operation of its laser filters. The new tool will allow the filtration system to self-optimize, no longer requiring an operator to manually adjust the filter depending on the contamination level of the recyclate input.

    The technology has been under development for the past two years and uses machine learning and sensors to automatically adjust the filter to the contamination level. It is a "milestone" for Erema, Hackl said, and a big benefit for the customer in terms of convenience paired with low risk as well as reduced waste.

    Visitors on the show floor can also expect a new machine addition to Erema's portfolio, a size 2325 Intarema TVE, its largest so far for polyolefins. The recycling system handles high, low and linear low density polyethylene and polypropylene with a capacity of up to 4,000 kilograms per hour.

    "This is the first time we [have built] such a big machine for polyolefin recycling," Hackl explained. "Until now, we had reserved these big throughputs and big lines for PET. We've applied all those learnings into polyolefin recycling."

    The machine is undergoing testing at Erema's facilities during the next weeks and should hit the market after Fakuma.

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