From Supply Chain To Supply Cycle

from Supply Chain to Supply Cycle from Supply Chain to Supply Cycle

Ch i Slijkh iChris Slijkhuis

Director Sourcing and Logistics

What is necessary to produce 1 ton of plastics?

approx. 900 liter crude oil

approx. 2 tons e-waste

approx. 14.000 kWh

approx. 950 kWh

OR

pp

OR<10% of the energy consumptiongy p

2-3 kg reduction of CO2 emissions per kg of recycled plastic

Agenda Presentation Speed Chain 2009

R L i ti i El t iReverse Logistics in Electronics

De-Pollution Ferrous/Non-Ferrous Metal SeparationDe Pollution, Ferrous/Non Ferrous Metal Separation

Tech Plastics meet their Re-Maker

Converting the Supply Chain into a Supply Cycleg pp y pp y y

Forward & Reverse Logistics

Producers in forward flow(users in reverse flow)

Users in forward flow(producers in reverse flow)

h ld & DistributorsWholesaleRetail

RawMaterialsProducer

ManufacturerHouseholds & Institutions

Different ReverseDifferentManufacturer Intermediaries

Recyclers Rest fraction= waste

New Markets

Reverse FlowForward Flow

Th RThe new „ReverseIndustry“

Reverse Logistics – from Supply Chain to Supply Cycle

Returns logistics:

New Components Build

Certified Reprocessing Deliver

CertifiedReprocessing

Closed Loop Recycling

Raw Materials

• Product repair• Product upgrades

End Of Life Take back

Return toSuppliers Sort/Inspect

Customer Usage

Third PartyRecycling

Remove

Materials forRecycling• End-Of-Life Take back

Recovery Re Manufacture and Recycling

Disposal GoalZero Landfill

Dismantle

AlternativeUses

Recycling

Recovery, Re-Manufacture and Recycling• Asset recovery• Re-Manufacture• Re-Manufacture• Recycling• Liquidation managementq g

End-of-Life Legislation

Directive on Waste Electrical and Electronic Equipment (WEEE)q p ( )

Waste Electric and Electronics 1998 6 Mio Tonnes (4 %)

Growth of waste flow 3 times average municipal waste

Back in 1998 90 % of WEEE was landfilled or incineratedBack in 1998 90 % of WEEE was landfilled or incinerated

Special problem the hazardous content

Therefore 2 Directives: WEEE (reduction of electro-waste) &( )RoHS (restriction of hazardous substances in electronics)

WEEE Directive – Reduction electronic waste

Encompasses all Electrical & Electronic Appliances

Many Similarities with Packaging Waste Directive (1992)Many Similarities with Packaging Waste Directive (1992)

• Source Reduction (specifically hazardous substances)• Re-Use• Recycling • Incineration (thermal recovery)• Management of Restwaste

Consumers can Return without Costs

Targetted 4 kgs Waste per Inhabitant/Year (2005)

OEM Producers bear costs (to be included in Salesprice) OEM Producers bear costs (to be included in Salesprice)

Global End-of-Life Material Return Growing

Millions of tons of durable goods are shredded every year to liberate d th f d f t land recover the ferrous and nonferrous metals

The E-Waste Supply Cycle focussing on plastics

Shredder Ferrous-MetalsSi d i

De-Pollution

Non-Ferrous-Metals

S lt

Non-FE Separations

Size reduction, liberation and

separation

Smelters

Separate Non-Plastic Items

Further Separation Plastic/non-Plastic

Mixed Plastic Rich E-Waste

De-Pollution

Taking out

• Hazardous componentsHazardous components

• Big Condensators

• Printed Circuit Boards• Printed Circuit Boards

• Batteries

I li ith WEEE l• In line with WEEE laws

Recovering valuable components

Taking out fractions that disturb further separations

Shredding & Ferrous Recycling

Shredding Process

• “Cut” materials into pieces

• Shredders can be small to 6000 HP

Magnetic Ferrous Seperations

• Taking out FE-MetalsTaking out FE Metals

The Shredder Residue is raw material

Non-Ferrous Metals – Size Reduction & Air TablesSome examples of using physical properties of the Some examples of using physical properties of the

materials to Separate:

• Size

• Density

• Induction

• Colour

• Surface to weight ratio’s

Non-Ferrous Metals Separation - Smelting

Using physical properties of the materials to Separate:

• Size

• Density

• Induction

• Colour

• Surface to volume ratio’s

Smelting to concentrate and refine non-ferrous metals

• Copper• Copper

• Aluminium

P i M t l (G ld Sil P l di )• Precious Metals (Gold, Silver, Paladium)

df ll

Options for Plastics-Rich Streams after Recycling

Landfilling:banned in some countries, costs increasing, questions about pollution, lose important raw material

Incineration: (in many forms) costly and becoming more-so, questions about air pollution, capacity issues lose important raw materialcapacity issues, lose important raw material

Sell to brokers or directly to third world recyclers:might not be legal in some countries depending on material make-up rules always might not be legal in some countries depending on material make-up, rules always changing, some brokers come and go, does recycler adhere to acceptable environmental standards? What happens to byproducts?

Recycling in line with the European Standards:large customers require a more reliable and dependable solution, customers for these plastics can push feedstock to e-cycle suppliers, but need large volumes and p p y pp , gideally global presence to do this successfully.

Plastics Rich Material Quantity Growing

And tens of millions of tons of plastic-rich shredder residue that is mostly incinerated or land-filled

The Raw Materials

The avg. composition of the Sourcing Material EU

Other Plastics17%

Fluff/Foam

1% Wood

Ferrous & N-Ferrous1%

Wires & Elect Parts4%

Other Non-Plastics

PVC1%

Rubber3%

3%

PP3%

Fines1%

Other Non Plastics

1%

PC-ABS & PC6%

POM1%

HIPS27%

ABS-FR3%

PE1%

6%

ABS24%

HIPS-FR2%

PPO2%

3%

24%2%

May I invite you to one of our plants?

A joint-venture betweenMBA Polymers and

Müller GutenbrunnMüller-Gutenbrunn

LocationKematen an der Ybbs

Danube vincinity

Direct Rail-Connection (2007)(2007)

Near A1 Motorway

Easy access Western/ Eastern Europe

Capacity40 000 Tonnes per annum 40 000 Tonnes per annum

Goods-In, Analysis & Pre-processing

Sourcing & Goods InSourcing & Goods-In

• Material Handling

• Assaying

• Material Analysis

Pre-Processing

• Taking out remaining metals

• Cleaning material of minerals (glass, stones, dust)

• Eliminating organic fractions such as wood and rubberg g

Size reduction to a standard particle size

l l h h hConveying plastic material into high tech seperations

High Tech Separations & Extrusion/Compounding

Cleaning plastics

• Closed circuit water treatment

High-Tech Seperations

Obtaining ABS and PS• Obtaining ABS and PS

• In three grades

• Injection Moulding• Injection Moulding

• Extrusion

• General Purpose

High quality extrusion and compounding

• RoHS compliant products• RoHS compliant products

Laboratory services 24/24 hours

Incoming Material Analysis

• Yield & contaminations

Process Control

Numerous checkpoints• Numerous checkpoints

• In-time feed-back cycles

P it t l fi l d t• Purity control final products

Final products Quality Control

• Each big bag is quality controlled

• MFI, Izod and Tensile Strength

Why a High-Tech Global Footprint.......

Electronics OEM’s are Global and they demand: Electronics OEM’s are Global and they demand: • Global Supply of Plastics

Virgin like q alit of the tech plastics the se• Virgin-like quality of the tech plastics they use

• Large, dependable and consistent volumes

Consistent technical specifications• Consistent technical specifications

• A global answer to their Waste Plastics

• Reliable service levels• Reliable service levels

to become designed into become designed in........

Global Footprint to produce „Green Plastics“

EnglandCalifornia Austria

Guangzhou

The Challenges........

Rapidly changing environment • Legislation WEEE, RoHS, REACH, Waste Transport

Directives • The interpretation changes continuously• Import/export rules continue to change• Import/export rules continue to change

Post-consumer E-waste relatively “new”

Complex waste streams • Different types of plastics• Different types of plastics• Different grades

Developing a Global footprint

Products – ABS, PS, PP as pellets & compounds

Stable Properties with MBA Polymers’ Resins

MFR Analysis Type MBA PS 31309 0

10,0

n] a ys s ype S 3 30

8,0

9,0

kg) i

n [g

/10m

i

6,0

7,0

FR (2

00°C

/5k

4 0

5,0

MF

4,00 20 40 60 80 100 120 140 160

Samples

Some examples of recent green products

Europe - Electrolux

“Made with 55% recycled plastic, the Ultra Silencer Green from Electrolux is the most energy‐efficient cleaner on the market. Its new, high‐efficiency motor reduces the Ultra

Silencer’s energy consumption by 33% compared to a standard 2,000 watt vacuum cleaner. Because Ultra Silencer Green is made out of recycled materials, it is only available in black, as this color allows to achieve the best looking finish and quality when using

recycled materials. To signify Eco friendliness of the Green vacuum cleaner, Electrolux

designers added signature elements of green on the graphics and buttons.”

SOURCE: Electrolux Pressrelease

The World Economic Forum recognized MBA Polymers

Technology Pioneer 2006

The criteria for becoming this WEF recognition as Tech Pioneer are:

Innovation

Potential Impact

Proof of Concept

Growth and Sustainability

L d hiLeadership

Status

Thank you.

From Supply Chain To Supply Cycle

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