TechnoCompound to Present LGF Grades with PCR Content at Fakuma 2024

One development priority is on emission- and odor-reduced, long glass fiber (LGF) compounds for the automotive industry, specifically for vehicle interiors. The company can offer a growing number of ready-to-use (RTU) TechnoGreen grades based on polypropylene.

In addition, TechnoCompound's new Concentrate Dilution Concept (CDC) makes it possible to blend TechnoFiber LGF compounds for structural components with PCR to achieve the mechanical properties required for the application while at the same time reducing the finished products' carbon footprint to the greatest possible extent.

While some RTU grades containing PCR are already in use in massproduction applications, the new CDC solutions are currently under evaluation by OEMs. Another development project TechnoCompound will be presenting at Fakuma 2024 is materials for PCR-based packaging for the non-food sector.

Around 70% of TechnoCompound's compounds already contain recycled material, with 30% using PCR contents between 20% and 100%. These sustainable solutions help automotive suppliers comply with the End-of-Life Vehicle (ELV) Directive. TechnoGreen PP LGF grades with 20 to 50% fiber content have been on the market, and the new grades with PCR contents (21 to 35%) are in mass production, offering performance comparable to virgin materials.

Ready-to-use TechnoGreen PP LGF grades with fiber contents of 20 to 50 wt.% have long been marketed. They were initially available as compounds with PIR material (classes GK1 and GK2 according to the VW standard) for improving environmental characteristics. The company can now also offer TechnoGreen RTU grades with PCR contents (class GK4) of between 21 and 35 wt.%. Two of these are already in mass production. The special pultrusion process used by TechnoCompound results in high-quality compounds that perform as well as products based on virgin materials.

In addition to the RTU grades, TechnoCompound's new Concentrate Dilution Concept may be the right solution, in particular for structural components. TechnoGreen PP LGF 60 with a matrix of 100% virgin material (class GK1A) is used as the base material. This is blended in-machine with TechnoFin rPP, which consists of 100% PCR (class GK4). For example, when blended in a 1:2 ratio, it is thus possible to make carbon savings of 55% in comparison with processing virgin material with the same fiber content. A further advantage is reduced inventory, as material inputs are limited to two components instead of many when various prefabricated blends are processed.

Passed Stringent Tests

Several RTU compounds have passed stringent automotive tests and are used in Audi, Seat, Porsche, and Mini models. Applications include instrument panel (IP) carriers, which are subject to the strict limits for volatile substance and odor emissions applicable to interior applications.

Documented Sustainability

TechnoCompound is playing a pioneering role with certificates from its partner company ConClimate. These certificates, which state the PIR:PCR ratio, have been indicating the carbon footprint and carbon savings for all products since early 2023. Values are calculated using Substain software which, on the basis of recognized emission factors, provides carbon emissions (scope 1, 2 and 3) including packaging 'to gate' using TechnoCompound's factory gate as the default.

The company is also planning to be in a position to disclose its corporate carbon footprint shortly and to draw up a decarbonization plan in line with the Polymer-Group's sustainability goals. Along the entire value chain, these measures help complying with statutory, customer and social sustainability requirements, achieving the company's own environmental targets and meeting likely upcoming statutory requirements for recyclate content in new products.

As managing director Dirk Breitbach explains, 'It's 35 years that we've been using recycled materials to produce high-quality compounds. Thanks to strict quality standards, these products, as well as our new PCR-based solutions, meet stringent requirements across a wide range of applications. Our experience in the production, processing and application of these products means we can support customers in the automotive industry and other sectors right from material planning and optimization through to the start of mass production while boosting sustainability.'

Head of Sales Rifat Erden adds, 'Our standard TechnoFiber grades, our new TechnoGreen RTU compounds and the CDC (Concentrate Dilution Concept) with PCR components increase flexibility and are a strong starting point for our customers. This puts them in pole position in terms of sustainability and gives them an opportunity to win a long-term lead on their competitors.'