#Recycling / Circular Economy

2023-05-25

Innovative recycling to combat plastic waste

In view of the upcoming UN conference which aims to develop a legally binding agreement on plastic pollution, Covestro is emphasizing the need for more innovative recycling technologies, required to boost the currently low recycling rates of used plastics. Covestro has already achieved success with the development of its novel chemical recycling. In addition, the company plans to establish a global research center for processing plastic waste together with six other chemical groups.

Covestro drives forward technologies for recycling

Co-founder of planned research center for the chemical industry

In Paris, from May 29 to June 2, another round of international negotiations ("INC-2") will focus on drafting a global agreement against plastic waste pollution, which should be in place by the end of 2024. The international community initiated the process in spring 2022 at the United Nations Environment Assembly. According to the Organization for Economic Cooperation and Development (OECD), around 22 million tons of plastic waste, including microplastics, enter the oceans and the environment each year1. Without countermeasures, the annual amount could double by 2060.

"Resource consumption is on the rise and mountains of waste are growing – with negative consequences for the environment and climate. We urgently need to take countermeasures here and fundamentally change consumption habits and production patterns," emphasizes Dr Markus Steilemann, CEO of Covestro. "We need to make the circular economy a reality, and recycling is crucial here, in addition to the production of long-lasting and resource-conserving products. Covestro can and wants to play a central role in this."

Joint research center for processing plastic waste

Currently, the global recycling rate of plastic waste is only nine percent2. But with more recycling on an industrial scale, one study suggests that nearly 60 percent of plastic production could be met by recycled materials by 2050, reducing petroleum consumption by 30 percent3. This is where the World Economic Forum comes in, through its Low Carbon Emitting Technologies initiative, which promotes collaboration on a global scale to accelerate the development of low carbon emitting technologies for chemical production, including processing plastic waste. Seven international chemical companies, including Covestro, have signed a collaboration agreed to establish a research and development center together with the Dutch research institute TNO. Initial work will focus on the sorting, cleaning and conditioning of plastic waste to make it suitable for subsequent recycling technologies.

One key problem is that some types of plastic cannot be recycled, or can hardly be recycled at all. That is why Covestro is pushing the development of chemical recycling as an additional method. This involves breaking down used plastic into its chemical components so that new material can then be produced from these molecules.

Breakthrough for mattress foam recycling

Covestro has achieved a technological breakthrough for the chemical recycling of soft foam for mattresses. So far, around 40 million of these end up in waste incineration plants or landfills each year in the European Union alone4. With the new "Evocycle CQ-Mattress" process, the two central foam components can now be recycled. At the company’s Leverkusen site in Germany, this process is being further developed in a pilot plant with the prospect of industrial use.

The chemical recycling of rigid foam for insulating buildings and refrigeration appliances is the focus of a Europe-wide research project CIRCULAR FOAM initiated in 2021 and coordinated by Covestro. Here, 22 partners from nine countries are working together. If the material cycle can be closed, around one million metric tons of waste and three million metric tons of CO2 emissions per year could be saved in the European Union from 2040.

In order to also improve the recycling of food packaging made of paper and cardboard, Covestro has been offering a new development on the market since May 2023. For this purpose, the company has developed a special coating material that, unlike conventional coatings, can be recycled together with the packaging. It is also produced itself in the spirit of circularity - with raw materials that are partly based on plants.

1 Source: Global plastic waste set to almost triple by 2060, says OECD

https://www.oecd.org/environment/global-plastic-waste-set-to-almost-triple-by-2060.htm

2 Source: Plastic pollution is growing relentlessly as waste management and recycling fall short, says OECD

https://www.oecd.org/environment/plastic-pollution-is-growing-relentlessly-as-waste-management-and-recycling-fall-short.htm

3 Source: Recycling and the future of the plastics industry | McKinsey

https://www.mckinsey.com/industries/chemicals/our-insights/how-plastics-waste-recycling-could-transform-the-chemical-industry

4 Source: The End-of-Life of Flexible Polyurethane Foam From Mattresses and Furniture - Europur

https://europur.org/the-end-of-life-of-flexible-polyurethane-foam-from-mattresses-and-furniture/

Covestro, FILK Freiberg, and OUT e.V. develop flexible, conductive polymer smart textile system

As the smart textiles market continues to grow across healthcare, personal protection, sportswear, and automotive applications, developers are seeking new ways to integrate electronic functionality directly into textiles, without the rigidity and complexity of conventional wiring. To address this challenge, FILK Freiberg Institute, an independent research institution with expertise in polymer coatings for textile applications, collaborated with Optotransmitter-Umweltschutz-Technologie (OUT) e.V. The joint project, funded under the German Industrielle Gemeinschaftsforschung (IGF) program of the Bundesministerium für Wirtschaft und Energie (BMWE), focused on developing flexible, conductive polymer surfaces for next-generation smart textiles.

Covestro to exhibit solutions for a more sustainable and productive textile industry at Techtextil 2026

Covestro will present a broad portfolio of material innovations for textile coatings, adhesive films and thermoplastic polyurethanes (TPUs) at Techtextil 2026 (Hall 11.0, Booth C79). The exhibits will demonstrate how advanced solutions can enhance durability, recyclability and manufacturing efficiency across applications such as automotive, infrastructure, protective apparel and sportswear. A particular focus will be on more sustainable coating technologies, including antimicrobial systems based on INSQIN® in combination with AGXX from Heraeus Precious Metals, as well as the integration of Pontacol® thermoplastic adhesive films into Covestro’s offering.

Covestro showcases monomaterial concept in autonomous SUE People Mover

UE | STUDIOS has unveiled the fully autonomous electric minibus “Self-driving Urban E-Shuttle” (SUE), placing strong emphasis on sustainable material design. Developed within a project funded by the Federal Ministry for Economic Affairs and Energy (BMWE) and the European Union, the vehicle will begin public road testing this year. At the core of the concept is the consistent use of recyclable monomaterials to improve circularity at end of life.

Covestro and Heraeus Precious Metals collaborate to enable safer, more sustainable antimicrobial textile coatings

Laboratory tests reveal that AGXX antimicrobial surface technology from Heraeus Precious Metals is fully compatible with Impranil® PU dispersions which are part of the waterborne INSQIN® textile coating technology from Covestro, paving the way for more sustainable antimicrobial textile coatings. This discovery comes at a key moment for the textile coatings industry. As the sharing economy continues to grow, more people are coming into regular contact with high-use surfaces, creating ideal conditions for bacteria, viruses, and other microorganisms to thrive.

Reju opens its first R&D Center in the U.S. in Conshohocken, Pennsylvania

Reju, the company specializing in textile regeneration, today announced the opening of a Research and Development (R&D) Center in Conshohocken, Pennsylvania, the company's first proprietary research center in North America. Located within Technip Energies' existing Advanced Materials and Catalysts research center, the lab will allow Reju to accelerate the rollout of its recycling technologies and develop its next-generation circular solutions.

New skills for a circular textile economy

Based on the results of a comprehensive analysis, the Erasmus+ project Skills4Circularity is developing three practical training modules covering recycling technologies, eco-design for the circular economy and sustainable manufacturing. The content of the first module, Recycling Technologies, has now been developed and validated together with industry representatives. The module provides participants with knowledge of regulatory requirements, material sorting and the preparation of textile waste for recycling.

Itema reaffirms its commitment to the Syrian textile industry at NasTex 2026

From July 18th to 21st, Itema will exhibit at NasTex at the Damascus Fairground (Hall 11 – Stand C02), marking its return to one of the Middle East’s historically significant textile markets. Itema will showcase advanced weaving technology designed to support the competitiveness and technological evolution of Syrian manufacturers and announces a new partnership with Growfast Agency as the sole agent of Itema in Syria.

KARL MAYER's HKS 2-SE Expands Possibilities for Premium Stretch WARP KNITS

Warp knitted fabrics with a woven look are more in demand than ever in the fashion and apparel industries. Stretch WARP KNITS, in particular, impress with their freedom of movement, breathability, and virtually wrinkle-free wear – thereby opening up new style worlds such as smart casual or business casual. When it comes to the highly efficient production of premium-quality stretch WARP KNITS, the HKS 2-SE has long been the machine of choice. KARL MAYER’s best-selling tricot machine produces standard elastic fabrics characterized by high gauges, smooth, delicate surfaces, and a soft hand feel.