- Our approach
- Our performance
- LIGHTWEIGHT, HIGH-GLOSS CAR SOLUTIONS
- IMPROVED PRODUCTIVITY IN COLOURING
- HIGH-PERFORMANCE, LIGHTWEIGHT STRUCTURES
- SUSTAINABLE AUTOMOTIVE INTERIOR SOLUTIONS
- SAVING CUSTOMERS’ PRODUCTION TIME
- OPTIMUM THERMAL INSULATION WITH STYRENICS
- SAFE AND RELIABLE HEALTHCARE APPLICATIONS
- ENERGY-EFFICIENT CUPS FOR HYGIENIC PACKAGING
- SUSTAINABLE SELECTIVE LASER SINTERING
We strive to provide sustainable solutions to our customers and end-consumers by taking a responsible approach to our product portfolio across the entire value chain.
As the global market leader in styrenics, we take a responsible approach to our product portfolio looking at the entire value chain – from procurement, development and production towards transport and sales, and from integration into customer processes to intended use. Together with customers and the scientific community, we engage in collaborative innovation of cutting-edge sustainable products. By driving product stewardship and quality management, we ensure compliance with product regulations and deliver safe, best-quality and high-performance products to our customers. Together with associations and our business partners, we are striving to achieve high and well-acknowledged sustainability standards in the styrenics industry.
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KEY HIGHLIGHTS 2017
In 2017, we actively worked on circular solutions for polystyrene through depolymerisation projects.
OUR SUSTAINABILITY TARGETS
In order to demonstrate our commitment to provide improved sustainable solutions for our customers, we started to define clear global sustainability targets in 2014. These targets are aligned with our material topics and underscore our commitment for continuous improvement.
For product sustainability, we aimed to bring our sustainability quota for all research and development projects – be it global R&D or regional development centre projects – to above 90%. A comprehensive analysis of all global R&D and regional development projects in our innovation pipeline undertaken in 2017 shows that our Global R&D/ Intellectual Property unit, which drives fundamental, mid-to-long-term oriented developments, maintained its high level of more than 90% of projects having a positive sustainability impact. Regional development projects achieved above 80%, hence, on average all our R&D projects worldwide have a positive sustainability rating of 90%. This is the highest ever achieved within the company to date.
We are also working on a proof of concept for promising depolymerisation technologies for polystyrene by 2019, through our close collaborations with leading research institutes and partners along the value chain.
In 2017, we received a grant from the German Federal Ministry of Education and Research for a research project on recycling polystyrene post-consumer waste. We also entered into partnerships with Agilyx, an environmental technology and development company, and Pyrowave, a recycling technology provider, to develop polystyrene recycling solutions in North America.
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This material solution is 10% lighter than PMMA or other traditional materials. A car with six pillar covers made from Luran HH-120 saves about 90 grams of weight per car. This may not sound like much, yet considering 100,000 cars and an average mileage of 20,000 km per year, savings of up to 20,000 kg of CO2 emissions can be realised. Luran® HH-120 also has an advantage in terms of injection moulding cycle time, which also has a positive impact on CO2 emissions.
In addition, Luran HH-120 has been optimised in terms of scratch resistance. A special formulation reduces the vulnerability against scratches and makes scratches less visible. The transparent base material allows for an excellent colour depth and therefore avoids costly painting, which helps to save emissions, energy and processing steps.
Our high-grade polymer Luran® S KR 2864C can be processed with the ColorForm technology developed by KraussMaffei, which provides a more cost-efficient alternative compared to traditional painting. This new technology sets new standards in terms of efficiency as the paint is directly injected between the mould and the part surface with no second work step needed. It is, in addition, extremely scratch-resistant due to the polyurea coating from PANADUR, a manufacturer of functional surface systems based on polyurea. This coating ensures longer-lasting quality and sustainability.
LURAN S KR 2864C IMPROVES PRODUCTIVITY, AS THE USE OF POLYUREA ELIMINATES THE NEED FOR MOULD RELEASE AGENTS, RESULTING IN A SIGNIFICANT REDUCTION OF THE PROCESS INTERVAL PERIODS, MANUFACTURING COSTS AND WORK WASTE DUE TO A DROP IN REJECT RATES.
In comparison to conventional materials, continuous fibre-reinforced plastics offer not only a high weight reduction potential, but also a variety of functional advantages. Based on SAN and a proprietary, patented process technology, INEOS Styrolution developed StyLight® – a new generation of high-performance thermoplastic composite, combining mechanical strength with high aesthetic value.
Thermoplastic composite sheets from INEOS Styrolution can be thermoformed, back-injection-moulded and decorated in just one processing step. In addition, StyLight features very high stiffness and high dimensional stability allowing thin wall design, resulting in weight reduction.
The lower shrinkage during the cooling step of the styrenic copolymer matrix, based on a modified SAN, reduces the surface roughness or waviness significantly, offering superior surface quality. This allows for various aesthetic surface effects, such as film decoration, easy painting and printing. This composite sheet not only ensures aesthetics, structural strength and performance, but also addresses megatrends of our time, such as energy and resource efficiency in the automotive industry.
According to recent studies in automotive engineering, such fibre-fabric-reinforced plastics offer a thickness reduction of 50–70%, which results in a weight reduction of up to 50% versus standard injection-moulded plastic design, reinforced with structural plastic, metal or made of SMC.
Moreover, our recently introduced and enhanced carbon look composite StyLight Aesthetic S C245-1 offers a recyclable thermoplastic solution with the aesthetic appearance of an Epoxy carbon – a thermoset resin made in a resin transfer moulding (RTM) or autoclave technology, impossible to recycle.
INEOS Styrolution introduced the new carbon look composite StyLight Aesthetic S C245-1, providing a higher fibre density, improved mechanical properties, in particular enhanced stiffness and rigidity. With these new characteristics, StyLight Aesthetic S offers a surface quality that makes it even easier for manufacturers to replace steel.Because of its characteristics, StyLight is specifically targeting semi-structural applications for automotive interiors and exteriors. It is also an attractive solution for electronics as well as high-performance sport equipment.
GLASS-FIBRE-REINFORCED PLASTICS ENABLE A WEIGHT REDUCTION OF UP TO 40–50% VERSUS STANDARD SOLUTIONS.
In 2016, INEOS Styrolution released one of its most interesting material innovations, enhancing its dedicated portfolio of sustainable solutions for interior automotive applications. The new Novodur® Ultra 4255, a low-emission and high-heat ABS, features high impact strength at room as well as low temperatures, 100% ductility at -30°C and high heat resistance. In addition, best in class flowability properties ensure easy processing and the related cost advantages for this application. The new Novodur Ultra gained significant momentum in the automotive industry and is well received as the material of choice for interior applications, such as door panels, lower seat trims, centre and overhead consoles and glove box doors and frames.
NOVODUR® ULTRA 4255 PROVIDES 5% MATERIAL SAVINGS COMPARED TO CONVENTIONAL ALTERNATIVE PC/ ABS DUE TO LOWER DENSITY AND WALL THICKNESS.
The newly developed Novodur® Xspray is an eco-friendly ABS alloy – especially developed for the Asia-Pacific market – that combines excellent paintability for high luminance spray painting and good chemical resistance, hence eliminating the need for the primer treatment process. The material had been selected by various Household and Electronics manufacturers for state-of-the-art refrigerators, washing machine parts and vacuum cleaners in Asia. This project has high multiplication potential for other regions and applications.
NOVODUR® XSPRAY SAVES THE STEP OF APPLYING A PRIMER COAT ON THE SURFACE, PRIOR TO PAINTING.
This system for building glass facades is the first of such applications in the market made from styrene-based polymers, meeting the highest standards in terms of design, comfort, safety and energy efficiency. Luran® S 778T G2 UV, an 8% glass-fibre-reinforced ASA grade, offers a clear advantage in terms of UV resistance and shrinkage compared to other plastic solutions. Well-suited for metal-plastic combinations and structural parts for outdoor applications, it features high impact strength and dimensional stability, best-in-class weatherability as well as low thermal conductivity.
LURAN S 778T G2 UV HELPS TO IMPROVE ENERGY EFFICIENCY AND SUSTAINABILITY AND STANDS OUT DUE TO ITS HIGH SURFACE QUALITY AND LONG-LASTING AESTHETICS.
In cooperation with Technoform Glass Insulation, we established a window spacer made of Luran® 378P G5. Luran 378P G5 is the obvious choice for this window spacer as it met all of Technoform’s requirements, especially the need for a lower thermal conductivity.
An additional challenge in the development phase was to find the optimal balance between thermal conductivity and stiffness. An advantage of Luran compared to other plastic materials is its comparatively low thermal conductivity, which enables better thermal insulation for added sustainability. Low VOC emissions, excellent colour fastness over extended periods, high stiffness and impact resistance are also features that speak for this solution and make it the perfect material for construction applications.
DUE TO THE OPTIMISED THERMOCONDUCTIVITY, THIS WINDOW SPACER MADE OF LURAN 378P G5 IS MORE SUSTAINABLE AND COMPLIANT WITH STRICTER ENERGY REGULATIONS COMPARED TO OTHER ALTERNATIVE SYSTEMS ON THE MARKET.
Styrolux 4G60 has been specifically designed for the development of medical drip chambers in IV sets. This new grade represents the first solution of the fourth generation of advanced copolymer materials. This dedicated grade for drip chambers not only excels in softness, elasticity and transparency, it also offers good flowability and high impact strength. Very good bonding properties make this new grade an excellent fit for the production of drip chambers.
Styrolux 4G60 is available with the “Essential HD Package” with a signed long-term supply contract. The package includes up to 12 months Notification of Change (NOC).
COMPLIANT WITH USP CLASS VI AND SELECTED ISO 10993 STANDARDS.
Polystyrene cups exhibit high mechanical strength at low weight, do not require pre-drying and consume less process energy compared to other plastic materials. In fact, the production of polystyrene requires approximately 60% less energy than polypropylene, and 40% less energy than PET.
POLYSTYRENE REQUIRES ABOUT 60% LESS ENERGY THAN POLYPROPYLENE AND ABOUT 40% LESS ENERGY THAN PET
Global R&D is developing a new product for 3D selective laser sintering (SLS). The new material is a powder-grade styrenics blend, suitable for printing prototypes and small series items in an additive manufacturing process. The powder grade developed for 3D printing offers sufficient mechanical properties, low shrinkage as well as low warpage properties and a good surface quality. In the SLS process, the powder also shows a multitude of sustainability features, such as a robust processability, faster cycling times, a lower energy consumption due to a lower powder bed temperature as well as a higher recycling rate (currently 50% waste).
The German Federal Ministry for Economic Affairs and Energy (BMWi) has decided to grant €650,000 from the 6th Energy Research Programme of the German Federal Government for the development, which covers about 50% of the total project costs over three years.
THE NEW BLEND FOR SELECTIVE LASER SINTERING PROVIDES A MULTITUDE OF SUSTAINABLE FEATURES, SUCH AS FAST CYCLING TIMES, A LOW ENERGY CONSUMPTION AND A HIGH RECYCLING RATE.