2023 Sustainable Innovation in Material Nominees
Amcor Rigid Plastics (ARP) – PowerPost™ lightweighting technology
PowerPost™ technology is the most advanced lightweighting technology for hot-fill beverages on the market today. Polyethylene terephthalate (PET) bottles created using PowerPost can be made with up to 100% recycled material and are fully recyclable. PowerPost technology reduces waste by delivering a bottle nearly one-third lighter, with 30% energy reduction and 30% carbon savings over most 20 oz (600 ml) bottles available today.
By eliminating the vacuum panels, PowerPost offers increased design freedom, premium appearance, and consumer appeal. Eliminating the panels in the body also drive operational improvements at the fillers and allows bottle labels to be applied more efficiently.
Avient Corporation – Cesa™ Nox A4R Additive for Enhanced Recycling
As the content of PCR in packaging articles continuously increases, it becomes more and more important to understand how to best protect the polymers during the recycling process in order to achieve the smallest possible accumulation of degraded and colored material.
Cesa™ Nox A4R does not only show improved stabilization of Polyethylene in up to 3 full recycling loops, but it also broadens the processing window of recyclers and converters by increasing the polymer degradation temperature (OOT) by up to 40 °C; it also reduces the yellowing of the polymer and the gel formation during the recycling process.
Protecting PCR from degradation in this way can help achieve higher quality levels of recyclate, better end-use products, and improve the quality of the overall recycling stream due to its long-term stabilizing effect.
Avient Corporation – reSound™ Ultra-Low Carbon Footprint Thermoplastic Elastomers (TPEs)
Developed to support a global shift toward net zero CO2 emissions for next-generation products, these reSound™ TPEs are formulated to achieve negative product carbon footprint (PCF) values. The current grades in the series offer an industry-first PCF between -0.46 to -0.02 kg CO2 eq / kg product. The ultra-low PCF of this reSound™ TPE series measures the cradleto-gate stage of the product life cycle.
Avient is the first to globally launch and produce negative PCF TPEs with material quality equal to traditional materials, including colorability and appearance. In comparison, standard TPEs have a PCF around 3.5 CO2 equivalent kg / kg product meaning our ultra-low formulations provide a significant carbon footprint reduction.
We have aligned our methodology to ISO 14067:2018, the globally accepted greenhouse gas (GHG) emissions standard. We are in the process of certifying our process through an audit by TÜV Rheinland®. The GHG emissions are lowered by carbon sequestration, innovative compatibilization of unique raw materials, and leveraging Avient’s efficient and green manufacturing practices.
Envision Plastics – EcoPrime® Fit for food contact HDPE and PP PCR
EcoPrime® is a post-consumer recycled HDPE resin (HDPE PCR) with an FDA LNO for direct food contact up to 100% content for conditions of use C-H. EcoPrime® is made of postconsumer containers that started out as food packaging, and leveraging Envision Plastics’ patented, post-extrusion, and chemical-free devolatization process to decontaminate and clean the recycled resin by removing odors, volatiles, and semi-volatiles from the resin so that it is safe to be used again in direct food contact. We also have an FDA LNO for PP for direct food contact up to 100% content for conditions of use A-H and we leverage the same process to produce this product.
While EcoPrime® is most commonly used in blow molding, it can also be used in injection molding, as well as blown film and flexible packaging applications. Similarly, our FDA authorized recycled PP is also a drop-in PP PCR replacement for virgin PP that can be used in a variety of applications.
we believe we are the only company in the market with expertise producing commercial scale recycled HDPE for several years running that is fit for food contact. We have the broadest portfolio of FDA LNOs allowing more and more owners of food and beverage brands to incorporate PCR into their packaging. We are also leading the market with our fit for food contact recycled PP. Our fit for food contact material has replaced over 100 million pounds of virgin resin in single use plastics.
Okeanos Group LLC – Made From Stone
Okeanos has developed a patented compound using responsibly sourced calcium carbonate. Made From Stone is a new category of material technology enabling resin producers, manufacturers, and brands to immediately reduce up to 2/3 of the overall virgin plastic content of their products, significantly lowering their carbon footprint by a similar amount, while retaining all customer and supply chain relationships.
Calcium carbonate has long been used as a filler in packaging but has been limited to small percentages due to processing and density issues. Okeanos has resolved these problems, allowing the calcium carbonate to comprise most of the item, while allowing it to remain flexible, lightweight, and floatable. Okeanos works with resin producers, manufacturers and brands to introduce Made From Stone technology to their existing supply chains, connecting them with local stone and compounders who can manufacture Okeanos' specialized compounds locally.
PolyVisions Inc. – DuraPET
We are using rPET and proprietary compounding techniques to produce an engineering grade material suitable to replace ABS, Polycarbonate, and PC/ABS Alloys. This allows companies to produce products that are green and sustainable due to the circularity that can occur. DuraPET has properties similar to or better than materials that are not readily recycled like ABS and Polycarbonate. The shrinkage rate is equal to that of ABS and PC so it can be a drop-in replacement for those materials without costly tooling expenditures.
The DuraPET material has a 91% rPET content and can replace materials that are far less recycled like ABS and Polycarbonate.
Solvay – Amodel® Bios PPA
Amodel® Bios PPA is our new partially bio-sourced long-chain PPA made from non-food competing biomass and produced using 100% renewable electricity, presenting the lowest GWP among PPAs (to the best of our knowledge), the highest Tg (135°) among bio-based PPA, lower moisture absorption than 6T PPA, high elongation and weldline strength, excellent surface finish and colorability and exceptional dimensional stability and chemical resistance.
Amodel® Bios PPA is produced in Solvay’s Augusta, Georgia manufacturing plant. The plant addresses sustainability across three key dimensions: using renewable electricity, reducing water consumption, and reducing non-sustainable waste. Using 2018 as a baseline, the plant was able to utilize 100% renewable electricity while reducing water consumption by 15% while also reducing nonsustainable waste by 50 %.