Printing Substrates: End of Life Options Carolyn Burns Global Marketing Manager, DuPont Nonwovens
2 Outline DuPont s Activities End of Life Options: Descriptions Driving/Restraining Forces Examples Summary
The Vision of DuPont 3 To be the world s most dynamic science company, creating sustainable solutions essential to a better, safer, healthier life for people everywhere.
Our 2015 Sustainability Goals 4 Reducing Environmental Footprint Greenhouse Gas Emissions Water Conservation Fleet Fuel Efficiency Air Carcinogens Independent Verification of Site Programs Serving the Marketplace Environmentally Smart Market Opportunities from R&D Efforts Products that Reduce Greenhouse Gas Emissions Revenues from Non-Depletable Resources Products that Protect People
The US EPA has identified a waste pyramid to drive change 5 Solid Waste Management Hierarchy Source Reduction and Reuse Most Preferred Recycling/Composting Combustion with Energy Recovery Landfilling and Incineration without Energy Recovery Least Preferred
6 Landfills
7 How a landfill works Clay deposits act as natural buffers between landfill and surrounding environment Bottom and sides are lined with clay Drains collect leachate Ground wells are drilled to monitor groundwater quality Landfills are divided into cells, and only a few are filled at a time Layer of earth spread at end of each day to reduce odor and control vermin Each cell is capped with layer of clay and earth, seeded with grass Source: National Energy Education Development Project, Museum of Solid Waste, 2006
While the number of US landfills has declined, the average size has increased 8 Since 1990, the total volume of solid waste going to landfills dropped by 4 million tons, from 142.3 to 138.2 in 2006 Source - EPA
9 Landfill Trends Driving Forces Not all waste can be recycled or burned Proper design can prevent hazardous wastes from seeping into underground water supplies Landfills are being designed so organic waste is allowed to biodegrade (bioreactors) Can be sources of energy via methane gas either sold or burned to generate steam and electricity Restraining Forces Concern about leachates A new landfill may not be inexpensive to build and maintain Confusion exists about what landfills can provide for biodegradable materials Considered wasteful as end of life options for many materials that could be recycled or incinerated
10 Energy Recovery/Incineration
11 How an incinerator works Collection vehicles dump the waste in vast trenches Waste is pushed gradually into the oven which runs at 750-1000 C Heat from the waste is used in a boiler and steam is piped to a turbine generator to create electricity Heaviest ash falls into a collection point and passed over with an electromagnet Flue gases scrubbed to treat dioxins Gases pass through particulate removal system and are release through the stack
12 Incineration Trends Driving Forces Good for treatment of clinical and hazardous wastes where high temperatures destroy pathogens and toxins Good for mixed/contaminated plastics and complex materials Popular in countries where land is scarce Avoids the release of methane Restraining Forces Concern about risk of pollutants Filters to trap pollutants must be changed frequently Old incinerators may still release dioxins as well as varying levels of heavy metals Not in my back yard phenomenon is prevalent
Spittelau Incinerator in Vienna offers best practice example 13 The Spittelau Waste Incineration Plant Best Practice UN-Habitat 1996, Update 2002 The district heating plant at Spittelau generated 36,400 MWh of electricity in one year from 263,200 m³ waste deliveries, and heated 190,000 homes and 4,200 public buildings, including Vienna's largest hospital.
14 Recycling
A view of European plastics end of life handling and comparison to the US 15 Estimated US statistics for plastics: 75% landfill 18% energy recovery 7% recycle
16 Recycling infrastructure is in place Collection varies from community to community, four main methods: Curbside Drop-off centers Buy-back centers Deposit/refund programs Occasionally plastics sorted into their resin identification code before recycle Usually single-stream collection (all materials combined) Recyclables are sent to Materials Recovery Facility (MRF) for sorting from other materials, through a variety of methods: Manual Mechanical Magnetic
Facilities are equipped to handle many types of materials 17 Resulting mixed plastics are sorted by plastic type: Flotation Optical/Spectroscopy Air jets Sorted plastics are baled and sent to reclaimers At reclaimer, scrap plastic passed along shaker screens to remove trash, washed, ground into small flakes Flotation tank further separates contaminants Flakes dried, melted, filtered and pelletized Pellets used to make variety of finished products composite lumber, carpet, containers, etc
18 Recycle Trends Driving Forces Enables conservation of nonrenewable fossil fuels Reduces energy consumed Reduces amounts of solid waste going to landfill Can replace virgin 1:1 in certain applications Many well established applications exist with infrastructure in place Public perception is very positive Landfill costs are rising Restraining Forces Collection may be difficult if products are scattered Need an end market Needs clean stream of materials Confusion about which plastics are easiest to recycle or accepted in local facilities Sorting of filmic materials may be difficult in certain facilities Banning of disposable plastic bags which may be recycled Effort to recycle
19 Existing DuPont Tyvek recycling programs Envelopes In place in US for over 20 years Envelopes sent back to Richmond plant, baled and sold to recyclers Recycled into composite lumber, fencing, drainage pipes, playground equipment Banners In place in Malaysia for five years Collection of used banners by those who printed them Can also call DuPont for collection Recycled into composite lumber Boardwalk Sound barrier
20 Biodegradable/Compostable Intermediates Conversion Products Biowaste Collection Processing Starch, Cellulose Sun Compost Biological Degradation Harvesting Extraction CO 2 H 2 O Biomass Renewable Raw Materials Photosynthesis
Compostable and Biodegradable materials must meet specific definitions 21 For biodegradation, material is degraded into small pieces that can be used as a food source by microorganisms (bacteria, fungi, algae) and transformed into CO2, H2O, energy and neutral residue Takes place in many environments, such as soil, compost sites, water treatment facilities, marine environments Not all materials are biodegradable under all conditions Compostable materials must: Disintegrate rapidly during composting process Biodegrade quickly under composting conditions Not reduce the value or utility of finished compost Not contain high amounts of regulated materials
22 Plastics biodegradation requires two key steps 1. Long polymer chain cut at the carbon-carbon bonds by heat, moisture, enzymes, or other conditions depending on the polymer. Degradation: the plastic becomes weak and fragments (not a sign of biodegradation). Plastics Fragment Fragment Fragment Microbes CO2 H2O Humus 2. Shorter carbon chains pass through the cell walls of the microbes and are used as energy source. Biodegradation: when the carbon chains are used as food source and converted into water, biomass, CO2 or methane.
It s important to know the difference between degradable, biodegradable and compostable 23 Degradable plastics are designed to undergo degradation under specified standardized conditions Biodegradable plastics degrade from action of naturally occurring microorganisms must have molecules that are readily attacked and broken down by microbes Compostable plastics degrade by biological processes during composting at a rate consistent with other known compostable materials Plastics can be degradable without being biodegradable: it might disintegrate into pieces or invisible powder, but not be assimilated by microorganisms Plastics can be degradable and biodegradable without being compostable: it biodegrades at a rate that is too slow to be called compostable The difficult and controversial part of developing standards is how to spell out rate consistent with known compostable materials!
Current composting facilities are typically designed for organic wastes Organic waste fed to conveyor belt that takes it through sorting room where non-organic waste is removed 24 Large rotating mixers pulverize material and mix organic wastes Organic material loaded into long channels where water and a solid waste component are added to promote the decomposition After about a month of decomposition, the material is filtered and then sold as mulch
25 Biodegradable Trends Driving Forces Enables conservation of nonrenewable fossil fuels Public perception is very positive Landfill costs are rising Faster degradation of litter Composting facilities want to keep products free of nondegradable plastics that increase costs and lower quality Plastics manufacturers aim to develop large-scale markets for compostable plastics Restraining Forces Can interfere with recycling of plastics sorting difficulties Confusion about definitions Many require much higher temperatures to degrade than available in home composting Commercial facilities not widespread Littering could increase Chemistry strongly influences the degradability Landfills aren t compost heaps
26 Reduce/Reuse
27 Reduce packaging by using plastics wisely Deliver more beverage with less package Make food packaging more efficient Eliminate excess packaging Reduce transportation energy Trim waste Continuously improve through innovation
Plastics as materials for reusable items ensure that reuse can occur 28 The durability of plastic makes it an ideal choice for reusable items such as storage bins, sealable food container, and shopping bags Plastic produce crates are durable, easy to clean and cost effective By reusing containers, trash disposal costs are offset and less waste is sent to landfills Plastic pallets are impervious to moisture and many chemicals, so they can be used over and over
29 Reduce/Reuse Trends Driving Forces Consumers are aware of waste Lighter weights can mean lower freight costs Landfills are filling up or being eliminated Recycling and composting may be too complicated or even difficult Governments and companies are requiring reuse (eg banning shopping bags) Using less perceived as most economical Restraining Forces Packaging or materials not perceived as strong or protective enough Products may need special packaging for shelf life or shipping considerations Products made from recycled materials sometimes viewed as too expensive and/or inferior
Summary: A blend of recovery and end of life options creates efficient waste management 30 Overall life cycle impact should be taken into account Shifting waste from landfill will create savings of energy resources Recycling targets should be adapted to foster innovation Look at long term/big picture Measure success via economic prosperity, environmental stewardship, corporate citizenship No single country has all the solutions for plastics recovery
Summary: Perform activities that help achieve sustainability goals 31 Align with suppliers/partners equally committed to sustainability Pick reasonable targets for the future showing commitment Look for product/package designs that encourage sustainability Learn customers scorecards and how they rate or define sustainability Understand the environmental impacts of your product throughout life cycle Confirm the science behind each claim and have evidence Use appropriate and truthful language, don t greenwash
Use this website link to ensure claims and statements are accurate and appropriate 32 http://www.ftc.gov/bcp/grnrule/guides980427.htm Part 260 -- GUIDES FOR THE USE OF ENVIRONMENTAL MARKETING CLAIMS sec. 260.1 Statement of Purpose. 260.2 Scope of guides. 260.3 Structure of the guides. 260.4 Review procedure. 260.5 Interpretation and substantiation of environmental marketing claims. 260.6 General principles. 260.7 Environmental marketing claims. 260.8 Environmental assessment.
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