Plastic Resin Distribution: Connecting the Dots Between Suppliers and End-Users

(1A) Plastic Resin Distribution: Connecting the Dots Between Suppliers and End-Users

The plastic resin distribution industry plays a critical role in the global supply chain of plastics. This industry is responsible for sourcing, buying, and distributing various plastic resins, the raw materials used to produce plastics. Importantly, distribution companies act as intermediaries between manufacturers, processors, converters, and end-users. These companies offer various services, including warehousing, logistics, transportation, and technical support. The global plastic resins market is projected to grow at a compound annual growth rate of 4.5% from 2022 to 2030.

What is Plastic Resin?

Plastic resin refers to the raw material used to create plastic products. Resins are synthetic materials made from various polymers, which are long chains of molecules with similar structures. In fact, Statista reports, “The demand for plastics has grown exponentially since it first became commercially available more than half a century ago. Since then, plastics have become massively important materials that are used in all walks of life, from electronic products, textiles, automobiles, and construction. Innovations in plastics have also revolutionized the medical sector.” The most common types of plastic resins used in the industry include polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), and polyethylene terephthalate (PET).

Lone Star Chemical Distribution Company
Lone Star Chemical Distribution Company

What Does a Plastic Resin Distribution Company Do?

Primarily, a plastic resin distribution company acts as a bridge between plastic resin manufacturers and end-users. These companies buy plastic resin in large quantities from manufacturers and store them in warehouses. Then, they sell smaller amounts of resin to processors, converters, and end-users. The distribution process involves several components, including the following:

  1. Sourcing: Plastic resin distribution companies source their raw materials from a variety of manufacturers around the world. They must ensure that the plastic resin they purchase meets their customers’ quality and quantity requirements.
  2. Warehousing: Once the plastic resin is sourced, it is stored in a warehouse until it is sold to the end users. Plastic resin distribution companies must ensure the warehouse facilities are suitable for storing the specific types of plastic resin they are handling.
  3. Logistics: Once a customer orders, the plastic resin distribution company must ensure that the order is fulfilled and delivered on time. This process involves managing transportation logistics and coordinating with freight companies to ensure timely delivery.
  4. Technical Support: Plastic resin distribution companies provide technical support to their customers to ensure that they use the plastic resin correctly. This suport often includes assistance with product selection, testing, and troubleshooting.

 

Who are the Customers of Plastic Resin Distribution Companies?

Included in their list of customers, plastic resin distribution companies serve a varied group. To name a few, they serve plastic processors, converters, and end-users. Plastic processors and converters are companies that take plastic resin and convert it into finished products. On the list of finished products you find common items such as plastic bottles, bags, and containers. Conversely, on the uncommon end, you find highly specialized items like medical devices. End-users, such as automotive manufacturers and construction companies, use plastic products as part of their manufacturing process.

In short, the industry is critical to the global plastics industry. With plastic resin distribution companies, the production of plastic products is much more manageable. Manufacturers deal with the logistics of shipping and storing raw materials. By acting as intermediaries between the petrochemical plants and the manufacturers, plastic resin distribution companies make it easier for businesses to access the raw materials they need to produce their products in a timely and budget-conscious manner.

Plastic: It’s Not All the Same The History of Polyethylene

Plastic: It's Not All the Same The History of Polyethylene

Almost every product in the 21st century requires plastic in one form or another. The invention of plastic endures as one of the greatest achievements of science and industry. Since its accidental discovery it has evolved into the material of our lives. The car seat you strap your child into, the point-of-sale system your Starbucks barista swipes your card on: both incorporate plastic. The same with the car you drove to get to Starbucks and even the very shirt on your back. Plastics have gone from being “just plastic” to being one of the single greatest contributions to life as we know it today.

THE ACCIDENTAL DISCOVERY

Missed Details and Accidental Success

In 1933, while running experiments on different elements, two chemists accidentally created one of the biggest assets of the 20th and 21st centuries. It all came with a little help from oxygen. Upon applying extremely high pressure to a mixture of ethylene and benzaldehyde, they produced a white, waxy material.

Polyethylene was discovered by accident in 1933 in Northwich, England. The two scientists, Eric Fawcett and Reginald Gibson, working at  Imperial Chemical Industries (ICI), stumbled upon this new substance. During their experiments, a test vessel leaked, leaving trace amounts of oxygen in their ethylene samples. The oxygen acted as an initiator, creating a substance previously unknown to man. Life as they knew it would soon drastically change.

Because the reaction had been initiated by trace oxygen contamination in an apparatus, the experiment was difficult to reproduce at first. It was not until 1935 that another chemist working for ICI, Michael Perrin, pushed matters further. He advanced this accidental process into a reproducible high-pressure synthesis for polyethylene. That process became the basis for industrial low-density polyethylene (LDPE) production, beginning in 1939. The following image is a pillbox made from the first pound of polyethylene produced at the ICI. This box was a commemorative gift presented to a member of the research team. (First polyethylene pillbox – Photo credit: Wikipedia.) Interestingly enough, polyethylene is still used for holding pills today.

Lone Star Chemical polyethylene pill holders
Lone Star Chemical polyethylene pill holders

Polyethylene Timeline

From WWII to Everyday Use

Before there was the “plastics industry,” there was just plastic. For decades, plastic provided abundant goods that exhibit qualities of being durable, light weight, and inexpensive. As American industry grew, the plastics industry grew with it, helping propel the United States into an industrial giant.

POLYETHYLENE IN WWII

1939- 1945:Military Secrets and Banned Substances

The war that changed the world also heralded the era of plastics. During World War II, polyethylene was a military secret. First used as an underwater cable coating, polyethylene came to serve a critical role in insulating material for military radar insulation. Polyethylene’s light weight and thin structure made it possible to place radar equipment on airplanes.

Additionally, because polyethylene was found to have low-loss properties at high frequency radio waves, commercial distribution in America was suspended once the war broke out.

Polyethylene Post WWII

The 1940s-1980s

After the war, polyethylene became a tremendous hit with consumers. It became the first plastic in the United States to sell more than a billion pounds a year. The landmark breakthrough in the commercial production of polyethylene began with the development of catalysts that promoted the polymerization at mild temperatures and pressures. As commercial production boomed, the American people took notice.

The Feachem Totem

2009

Feachem Totem
Feachem Totem

George Feachem, a young chemist, was on duty that fateful night of accidental success. Feachem witnessed the discovery first hand, but he never could have imagined the impact it was to have on the world.

A pill box presented to a technician at ICI in 1936 made from the first pound of polyethylene. Photo Credit: Wikimedia Commons
A pill box presented to a technician at ICI in 1936 made from the first pound of polyethylene. Photo Credit: Wikimedia Commons

George Feachem died in the late 1970s. It wasn’t until 2009 that his grandson, Chris Browning, discovered a small, triangular, plastic medallion inside an old wallet found in a drawer of Feachem’s possessions. Intriguingly, it bore the inscription “Dec 1938.” The medallion was attached to a small brass clasp engraved with his initials, “G.F.” After making enquiries, the family discovered that George’s secret keepsake was a sample of the very first ton of polyethylene ever produced. Mr. Browning has since submitted this first piece of polyethylene to the BBC History of the World project in recognition of his grandfather’s work.

Polyethylene Today

US Polyethylene Market
US Polyethylene Market – Photo Credit: PLG Consulting

In 1995, Jeffrey Meikle authored his book American Plastic: A Cultural History. In it, Meikle spoke candidly, stating “The ever-expanding proliferation of consumer goods has created an inflationary culture, and plastic has become the material of choice for this never-ending expansion. It is inexpensive, flexible, and less solid than wood or steel. It’s free of traditional preconceptions regarding its use and can be molded into any shape a restless drive for novelty might conceive… Plastic not only offered a perfect medium for this material proliferation, it conceptually embodied and stimulated it.”

Plastic packaging is the perfect example of material stimulation, just as Meikle observed. Among consumers, plastic packaging enjoys great popularity versus alternative packaging. Because of plastic’s light weight and ease of handling, manufacturers favor it. Plus, with plastic, production costs go down. Implementation of PET and plastic packaging leads to 90 percent weight reduction compared to glass, allowing a more economical transportation process.

Into the Future

The Polyethylene of Tomorrow

Polyethylene has propelled us through the years with unimaginable success. Success that shows no signs of stopping. In 2019 the beverage industry adopted recyclable PET (rPET), which led to a tremendous increase in production thanks to major participants such as PepsiCo and Coca-Cola. In July 2019, Coca-Cola announced that their subsidiaries would be embracing rPET as well.  Glacéau Smartwater, Honest Tea, and Chaudfontaine brands, as well as HBC water (a Swiss marketed product), will now be bottled in recycled polyethylene terephthalate.

And the beverage industry isn’t the only industry to make big mergers with polyethylene products. In 2020, BP PLC, a significant player in the oil and gas industry, developed an innovative enhanced recycling technology. This technology is capable of processing PET plastic waste, which too often goes unrecycled. BP plans to complete the pilot plant in the United States by 2023.

As of this year, the United States is currently producing 6 million more tons of PE per year than it did just five years ago. And yet, there is still room to grow. Five years ago, polyethylene represented one-third of domestic production; today it accounts for half.

Bringing it all together

Looking back and looking forward, we can’t escape the fact that plastics continually occupy the epicenter of economic growth. Our reliance on them as a society underscores the three basic, elemental things plastics do: assist, protect, and provide. They assist us in our daily lives, protect our food through packaging, and provide endless opportunities for tomorrow.

Plastic: It’s Not All the Same

Plastic: Its Not All the Same

Shaping the World Through Polyethylene

(Article 1 of 2 in the series)

With the shake of a hand, in the 1967 movie The Graduate, Mr McGuire gives Benjamin some career advice: “I want to say one word to you. Just one word… plastics. That’s where the future’s at!” If Mr. McGuire only knew how right he was. Some 400 million metric tons of plastics come into the world annually, from shoelaces to learjets. And plastic wouldn’t hold its position of prominence without polyethylene.

Polyethylene Stands Out: Shaping Our World

What is polyethylene?

Polyethylene stands out as the supreme plastic – most produced in the world. Many people, encountering plastics in every facet of their everyday lives, assume that all plastics are the same. Plastic is plastic, right? In truth, hundreds of polymers exist, but only a few touch our lives on a regular basis. Polyethylene, though, stands out as special.

In our times, petrochemical facilities produce 150 million tons of polyethylene annually. This accounts for 37 percent of the total plastics market. As the largest-volume polymer, polyethylene fills needs around the globe. Polyethylene, with its chemical resistance and ease of fabrication, enjoys wide popularity. Its molecular structure provides the key to its versatility. Safe for food and drink, highly recyclable, lightweight, shatter resistant, and inexpensive, polyethylene does it all. Advances in technology continue to improve its functionality, making polyethylene the most efficient of all uses of petroleum and natural gas.

The Chemistry of Polyethylene Stands Out 

Ethylene (C2H4) is a gaseous hydrocarbon commonly produced by the “cracking” of ethane, which can be distilled from petroleum. Ethylene molecules include two methylene units (CH2) linked together by a double bond between the carbon atoms—a structure represented by the formula CH2=CH2. Under the influence of polymerization catalysts, the double bond can be broken.

Molecular Structure

This simple structure, repeated thousands of times in a single molecule, holds the key to the properties of polyethylene. The long, chainlike molecules, in which hydrogen atoms connect to a carbon backbone, assume both linear and branched forms.

Chemists refer to the branched versions as low-density polyethylene (LDPE). They refer to the linear versions as high-density polyethylene (HDPE).The carbon chain length and extent of branching greatly affect the properties of the plastic. The illustration below contrasts the differing structures of the macromolecules for LDPE and HDPE. The amount of side-chain branching varies the closeness that molecules can come together. Closely compact chains give more rigid and solid plastics.

Image showing HDPE and LDPE chains.
Image showing HDPE and LDPE chains. Photo Credit: Research Gate

The Three Most Commonly Used Types of Polyethylene: PETE, HDPE, and LDPE

Collectively, polyethylene, the most common plastic in the world, falls into three classifications: Polyethylene Terephthalate, High Density Polyethylene, and Low Density Polyethylene. Here’s how they vary, just slightly, from one another:

Polyethylene Terephthalate – known as PETE, PE, or simply polyethylene, Polyethylene Terephthalate carries the reputation of being the most common plastic on earth. Lightweight and strong, it plays a vital role in the production of fabric and in the packaging of foods. Polyethylene can be manufactured in varying densities. Each different density of polyethylene gives the final plastic unique physical properties.

High Density Polyethylene (HDPE) – More rigid than both LDPE and PETE, HDPE plastic sheeting works ideally for water and sewer piping, snowboards, boats, roller chain sprockets, rebar, pulleys, and more. It ranks as one of the most popular materials used in thermoplastic engineering.

Low Density Polyethylene (LDPE)–  This density of polyethylene exhibits ductility, and forms a softer, clearer, more flexible version of HDPE. Often used as a liner inside beverage cartons, LDPE excels as the basis for corrosion-resistant work surfaces and other products. Still can’t picture it? Think plastic bags and bubble wrap. Both courtesy of LDPE.

Putting Polyethylene to Use

The Vast Applications of Polyethylene

As the most widely used plastic in the world, polyethylene serves as the raw material of products ranging from clear food wrap to detergent bottles to automobile fuel tanks. When it is slit or spun into synthetic fibers or otherwise modified, it takes on the elastic properties of rubber.

Polyethylene most often finds usage in beverage bottle plastics. Though hundreds of applications for PE exist, polyethylene furnishes the perfect material for water bottles and food packaging. According to the International Bottled Water Association, bottled water ranks as the most consumed beverage in the United States (by volume). According to a report of the International Bottled Water Association (IBWA), the per capita consumption equals more than 43 gallons of bottled water, a figure that is still rising. With trends like these, the demand for PE in bottled water packaging will surely keep increasing.

Polyethylene Terephthalate
Polyethylene Terephthalate - Photo Credit: The Physics Society

But don’t forget – polyethylene shows up in more than just bottles and packing. It fills a variety of applications. You undoubtedly encounter them at the supermarket. But other encounters abound. PE goes into tennis balls, bulletproof vests, and even glitter. It even makes chewing gum chewable. Believe it or not, chewing gum incorporates plastic. Manufacturers typically call it their “gum base” but if you dig a little deeper, you find that this base includes polyethylene.

polyethylene in vests tennis balls glitter.jpg 233 KB View full-size Download

We also encounter polyethylene in our toys, pipes, fittings, cable jacketing, and insulation. PE has come a long way. Globally, plastic food packaging accounts for 45 percent of the $1 trillion global plastic market.

Polyethylene Stands Out Today

Today, the food and beverage market comprises the largest source of demand for PET packaging. More than 70 percent of the soft drinks in the global market come packaged in PET plastic bottles. This means only 30 percent get packed with other materials, like glass and paper-based cartons, underscoring why products made from polyethylene stand out. In fact, attempting to replace plastics with an alternatives that perform the same function would increase environmental costs from $139 billion to $533 billion annually. Plastic enables us to do more with less. Polyethylene plastics are used in nearly every walk of life from everyday items to the unusual.

Additionally:

Bringing it All Together

Born from a scientific fluke, polyethylene has truly proven to be just as permeable and moldable as early indications suggested. The substance permeates, molds, and changes the world we live in daily. As the sun rises on tomorrow, the future looks bright. That is, of course, if we hang on to that one, simple, yet powerful keyword Mr. McGuire alluded to in The Graduate: plastics. It really is where the future’s at.

Single Use Plastics: Searching the Alternatives

Single Use Plastics: Searching the Alternatives

In 2022, if one seeks out trends in the plastics world, then talk about “single use plastics” surely scores high. This trend began some years ago and kept building. Just the same, 2022 stands as a high water mark for this topic.

The impetus for all this talk? The push, exerted by the environmental movement, to reduce plastics waste around the globe. Their foremost objective? To find alternatives to “single use plastics.” Environmental activists urge a switch to (1) biodegradable plastics alternatives, (2) non-plastic options, or (3) plastics products designed for re-use or recycling, not the trash heap.

Possible remedies number many, and even the plastics distributors themselves meet the challenge with new offerings. Companies such as this one—Lone Star Chemical—market a range of solutions.

Our series on “Plastics: What Lies Ahead?” examines the changes wrought by the market’s increasing aversion to single-use plastic products.

We also share a roundup of eye-opening directions, departures, and developments in the world of plastics, polymers, resins, and their like.

But understanding the trend begins with understanding public sentiment.

Sizing Up Single Use Plastics

Early in 2022, Deloitte Global surveyed individuals in the Gen Z and the Millennial generations. Deloitte wanted to assess their concerns about the state of the world. Deloitte reports that this population sector worries about the cost of living, climate change, wealth inequality, geopolitical conflicts, and the COVID-19 pandemic. Further, this sector shows determination to drive positive societal change. However, they struggle with daily life challenges. Challenges such as financial anxiety, lack of work/life balance, and consistently high stress levels.

“This year’s report shows that many Gen Zs and Millennials… reassessed what matters most to them. This has led to a workplace reckoning. It empowered many to demand sustained changes, including… more action to address climate change,” said Michele Parmelee, Deloitte Global Deputy CEO and Chief People and Purpose Officer.

Generational Shift

Nine in 10 respondents currently make an effort to protect the environment—primarily focused on everyday actions. Such actions include using second-hand and recyclable items or sourcing local and organic food.

Few respondents believe that businesses and governments do enough to combat climate change. As a result, Gen Zs and Millennials advocate for greater action. They put pressure on their employers to invest in visible, everyday environmental actions.

Actions where the employee can find direct involvement. A ban on single-use plastics stood as the No. 1 recommendation. Next came sustainability-oriented benefits and training—ultimately empowering employees to make greener choices in their everyday lives.

For more information and to view the full results of Deloitte’s 2022 Gen Z and Millennial Survey, visit: www.deloitte.com/genzmillennialsurvey.

What’s SUP?

Recently, SeekingAlpha.com reported that Canada unveiled a ban on single use plastics (SUPs). The financial news site stated that Canada’s comprehensive plan to reduce them extends to specific products. These include most plastic bags, disposable cutlery, and plastic straws, as well as stir sticks, cups, and six-pack rings that hold cans together. Some exceptions exist for medical needs and accessibility reasons, or other recognized specific cases.

Businesses that heavily rely on the material need to come up with new solutions. For instance, the restaurant sector, where plastic takeout containers, cutlery, and bags comprise the norm. Many problems plague the global supply chains since the pandemic. So tracking down plastic alternatives and procuring them becomes a daunting task. Especially for industries where margins remain thin.

Other countries that put in place various bans on single-use plastics include Chile, the U.K., and the European Union. However, the United States ranks as the world’s leading contributor of plastic waste. The United States generates about 287 pounds of plastics per person annually. Some states like New York and California put in piecemeal efforts, but the most action taken at the federal level simply increased the U.S. recycling rate to 50 percent by 2030.

Team Kōkua
Team Kōkua, Hawaiian Airlines’ employee volunteer group, at a clean-up event at Oʻahu’s Kaʻena Point State Park.

Single-Use Plastics Get Grounded?

Back in May, Hawaiian Airlines took the step of eliminating single-use plastics from cabins. In its Corporate Responsibility Report, the company cited its resolve to make the changeover by 2029.

Hawai’i’s hometown airline also reaffirmed its focus on sustainable tourism last fall. They provided tips on how Hawaiian’s guests can safely enjoy the islands while respecting communities, culture, and environment.

“We remain engaged with grassroots, industry, and political leaders,” said Hawaiian Airlines President and CEO Peter Ingram in the Corporate Report. The airline seeks to “shape a greener, more beneficial and equitable tourism economy.”

3M and Single Use Plastics

 
Meanwhile, some of the largest global corporations voice their enthusiasm for single-use alternatives.
 
3M launched its 3M Futures program, a new platform. Futures showcases five global science and technology trends shaping the world—and the future of tomorrow. The platform explores each topic alongside commentary from 3M experts, scientists, engineers, and designers. 
 
The 3M Futures topics for 2022 include Augmented Reality (AR) and Virtual Reality (VR); Artificial Intelligence; Sustainable materials; Pandemic Awareness; and Equity through Science and Technology.
 

“Every day, 3M’ers around the world… unlock the next phase of what’s possible. And they explore the latest trends in science and technology,” says Kevin Gilboe, head of 3M Design, International.

Among the key Futures findings: 

 
Respondents feel single-use plastics pose a bigger threat to the environment than fossil fuels and fast fashion.
To download full 3M Futures survey data, including by country and infographic breakdowns, visit: 3M Futures Resource Center
3M is launching 3M Futures
3M is launching 3M Futures, a new platform showcasing five global science and technology trends shaping the world today and helping to reimagine what comes next. (Photo credit: 3M)

Fashion Finds Sustainability

 
Fashion is not exempt from the sustainables push. 
 
Fair Harbor - Founders - Jake and Caroline Danehy
“We started Fair Harbor with the mission to mitigate the use of single-use plastics…” Jake and Caroline Danehy, the founders of Fair Harbor.
In July 2022, Fair Harbor, the fastest-growing sustainable apparel brand in the United States, re-emphasized its founding mission: to mitigate the use of single-use plastics. And to push forward and honor its commitment to environmental, social, and governance factors.
 
The company makes all of its signature beachwear from recycled plastic bottles, organic cotton, and recycled nylon. Since its founding, Fair Harbor recycled more than 27 million plastic bottles, preventing waste from entering the ocean. Additionally, the company implements ethical manufacturing practices, using only WRAP-certified, socially responsible factories.
 
Fair Harbor also encourages its customers to recycle their bathing suits through its Round-Trip Initiative. As community members look through their drawer of old swimwear or finish using their bathing suits, they follow three steps. They fill out a form, pack it up with a prepaid label, and send it back. Fair Harbor then sends the beachwear to 2ReWear, who gives them a second life as insulation and material for rugs.
 
To learn more about Fair Harbor, visit fairharborclothing.com.

Single Use Plastics and Hospitality 

 
And hotels show they can get into the act as well.
 
Fairmont Pacific Rim-FAIRMONT PACIFIC RIM ANNOUNCES THE ELIMINAT
Fairmount Pacific Rim, a Vancouver, British Columbia-based luxury hotel, has worked to reduce its single use plastics, making other innovations along the way as well.
In September, Fairmont Pacific Rim, Vancouver, Canada’s definitive luxury hotel, took a big step. Fairmont announced the elimination of non-essential single-use plastics from its guest journey. This includes its public spaces, guestrooms, dining venues, and spa. 
 
Since 2018, the company has been working on a comprehensive road-map towards the reduction of single-use plastics. The solution involves removing items entirely, identifying reusable alternatives, and/or introducing sustainable materials in their place. 
 
Recycle, Reuse, Rethink
 
Among Fairmont’s recent steps: 
 
Some 36,000 plastic key cards used annually… replaced by reusable FSC Certified cherry wood. 
 
Approximately 1,600 kilograms (198,700) of small bath amenity bottles used annually… replaced with large format refillable bottles.
 
Fully 600 kilograms of plastic water bottles consumed per year… removed from the guest experience and replaced with recyclable alternatives.
 
A total of 12,500 plastic laundry bags used per year… replaced with a re-usable cloth alternative. 
 
In-room amenities such as razors, toothbrushes, cotton buds, and shower caps… replaced with environmentally friendly versions.
 
All food and beverage take-away containers and cutlery… replaced with fiber-based solutions.

Single-Use Gets Doubly Emphasized

 
Phillips 66 saw a challenge to its management back in May when a shareholder resolution focused on the company’s plastics production.
 
The resolution received majority support (50.4 percent) from Phillips 66 shareholders. They request that Phillips 66 publish a report detailing how it could shift its plastic production business from virgin to recycled plastic polymers. In addition, assess its petrochemical assets under virgin-to-recycled transition scenarios of five and 10 years. Lastly, study the financial risks associated with such scenarios.
 
Phillips 66 jointly owns, with Chevron, the Chevron Phillips Chemical Company (CPChem). CPChem ranks as the 15th largest global producer of virgin plastic resins bound for single-use applications. Plastic Waste Makers Index supplied the data.
 
In its 2020 sustainability report, CPChem declared a goal to end its plastic waste. CPChem announced a recycled plastic polymer production target. 
 

For Every Door That’s Closed…

Not every bit of sustainables news in the plastics world has to be something to give pause. Some news proves encouraging and forward-looking.
 
The researcher firm known as Research and Markets (ResearchAndMarkets.com) issued its “Global Plastics and Composites Market Outlook Report” earlier this year. The report cites investments in upscaling technologies for chemical recycling and decoupling petroleum feedstocks for plastics. While that prospect might not sound thrill distributors of petrochemical-based plastics, the prospects hold potential and hope.
 
The “Outlook” provided an overview of the industry. It highlights disruptive, transformational, and competitive trends expected to impact industry growth.
 

Single Use Plastics Draw Focus

 
The study identified the top eight predictions for 2022 and discusses the potential implications for each industry segment. Key growth opportunities, companies to watch out for, and strategic imperatives for success come up for discussion.
 
The year saw protracted disruption of the supply chain because of natural calamities, ensuing force majeure events. Energy shortages, container shortages, and freight challenges continued to drive upward pressure on resin prices in 2021. Overall consumption registered a recovery of 4.5 percent in 2021 (in terms of volume). The unprecedented rise in resin prices resulted in revenue registering a robust growth of 16.1 percent in 2021.
 

Sustainability and Single Use Plastics

 
Sustainability and circular economy stand as the most important issues in the plastic industry. The pandemic and the ensuing disruption served as short-term impediments to the shift away from single-use plastics. But 2022 will witness a resurgence in downward pressure as legislations, restrictions, taxes, and bans are introduced (or will take effect) across geographies. 

The key material types analyzed in the study include polyethylene (PE), polypropylene (PP), and polyethylene terephthalate (PET). Also examined: Polystyrene (PS), engineering plastics, high-performance plastics (HPPs), polyvinyl chloride (PVC), polyurethanes (PU), and so on.
 
The main end industries covered include automotive, building and construction, consumer goods and household. Plus electrical and electronics, medical, packaging, and others. The latter includes industries as sports and leisure, agriculture, footwear, wind turbine applications, and oil and gas pipelines).
 

Toward the Future

 
Stakeholders across the value chain and end industries increasingly ramp up their collaborations. These include development of circular material flows in the wake of both tightening regulations and growing customer demand. Chemical recycling remains a mainstream, effective means of achieving circularity. Higher customer demand and the ever-growing investment in supply augur well for commercialization and scaling up of bio-based, greener plastics.

While some mega trends propel growth, others challenge the status quo. Diversified industry majors continue scouting for measures to strategically enable the shift of focus. They seek higher margins and sustainable and less-cyclical businesses. 
 
These comprise just some of the trends, and no doubt 2023 holds potential for further shifts in the landscape. Follow Lone Star Chemical’s social media feeds for the latest in the plastics revolution and the sustainability push. (Find our social channels at the bottom of the page, where the icons appear.)

Plastics Industry Provides Essentials for the Survivalist

Lone Star Chemical plastics for the survivalist_crop
The words “survivalist” or “survivalism” summon to mind a range of images, even emotions. For some these words evoke a picture of preparedness, security, and sensibility. For others, they conjure images of conspiracy-minded eccentrics bracing themselves for Armageddon or dystopia.
 
But even the most dedicated “survivalists” are individuals who likely think of their actions as simply exercising preparedness. And in that regard, can being prepared be all that unconventional? Setting aside, for the moment, the most radical fringe of survivalist devotees, the rest of that population (of preparedness types) starts to look fairly sane, even prudent. 
 
Insurance companies urge their customers to keep emergency supplies on hand, and even the government occasionally advises citizens to be prepared in the event of an extended lapse in community services or utilities. 
 
Call the survivalists or call them merely prepared, they are at least ready for anything and can rest easy when the electricity fails in the wee hours. Will the outage last for hours? Days? Weeks? THAT’S always the question. So why tempt fate?
 

A Survivalist Mindset

 
Close your eyes for a moment. Imagine going through the motions of beginning your day. Mentally walk through your morning routine — brushing your teeth, taking a shower, getting dressed, grabbing breakfast, maybe even making a coffee to take with you. Now imagine starting that day again, but this time, imagine doing so with no electricity, no running water, and perhaps even no shelter. What do you do? Disasters can strike anytime, anywhere throughout the year so preparedness is key. Effective preparedness measures taken today can mean the difference between life and death tomorrow.

“Real Life” Happens Whether We Expect it or Not

 
16 minutes. 
 
That’s how much time Oklahomans had On May 20, 2013  when a massive twister ripped through their town of Moore. Perched right in the center of some of the most storm prone territory on earth, Oklahomans are no strangers to tornados. But this was no ordinary storm. A massive, howling tornado pulverized a vast swath of the Oklahoma City suburb, chewing up homes and businesses and severely damaging a hospital and two elementary schools. These twisters have the power to fling automobiles like toys, to vanish houses and even neighborhoods in the blink of an eye – bulldozing insatiably ahead until it dissolves in an instant. And on this particular day, a monster of a storm was brewing. A twister over a mile wide with winds over 200 miles an hour was just beginning to form. Sirens rang out and a preformatted text meant to save precious seconds was sent to all residents: TORNADO EMERGENCY. The people of Moore had just 16 minutes. 
 
What would you do next?

16 Minutes and Counting

 
Any kind of disaster can happen in the blink of an eye. From tornados to car accidents to even a zombie apocalypse. And if it does, it’s usually the most prepared that survive (okay, the most prepared and the strongest). And while we can’t go to the gym for you, we CAN help you prepare with the use of plastics.

Want to Survive It?

Think Plastic.

Being prepared with a “go bag” or survival kit will always increase your odds of survival no matter the disaster before you. By supplying you with essential tools and supplies readily at your fingertips, even the most devastating disaster can be survived. Survival tools these days take on a myriad of forms, both high and low tech. No matter what, though, the best survival gear all comes down to one thing: practicality. And when it comes to survival, nothing is more practical than plastic! Gear made from plastic composites tend to be lighter than other materials but just as strong as heavier metals. So if you want to know what’s in our survival bag, here are our top 8 pieces of plastic gear for today’s modern survivalist.

  1. TG USB Rechargeable Plasma Lighter
    The TG Plasma Lighter is an electric arc lighter that can create flame even in rain. Essentially flameless, this lighter features a shell made of rubber and tough polypropylene, for extra durability. It charges via USB and reaches full charge in just 2 hours.
  2. Go Time Gear Life Tent and Emergency Survival Shelter
    This tube tent offers quick refuge when one needs an emergency shelter. Thanks to the included paracord, set up is easy and takes only minutes. Made of mylar, Life Tent is waterproof, to keep you warm and dry even in extreme conditions. Ultra lightweight, it folds nicely into a carrying bag and even includes a bonus emergency whistle.
  3. Vont LED Camping Lantern
    It can be nearly impossible to get anything done in the dark, which often happens unexpectedly when disaster strikes. Make sure to have these Vont LED Lanterns nearby! Compact, lightweight and easy to carry, the lanterns feature a polypropylene waterproof casing with an indestructible design that can survive a drop of up to 10 feet. On top of that, the lanterns come with enough batteries to deliver 90 hours of use per lantern so you never find yourself lurking around dark creepy corners ever again! (Just creepy, nicely lit corners)
  4. Wise Company Emergency Food Supply
    While the food ITSELF isn’t made from plastic (whew!), the storage container keeping your supplies fresh IS. The high-density polyethylene bucket is made from the perfect plastic composite. Polyethylene is durable with non-reactive thermoplastic elements that resist impact and inhospitable climates. As for what’s inside, this massive bundle of individually-wrapped meals-ready-to-eat offers enough food for up to 60 servings! To prepare each meal, only a small amount of water needs to be added, and there’s no cooking required. The food has a 25-year shelf life and is relatively compact, allowing you to fit several meals into a single bag for emergencies.
  5. LifeStraw Personal Water Filter
    Rather than carrying tons of water bottles with you, take this polypropylene straw. You use it just like any other straw, but LifeStraw filters out contaminants found in dirty water, including bacteria and parasites. The straw’s natural filtration system delivers safe, neutral-tasting water every time and lasts for up to 1,000 gallons.
  6. Gear Aid 550 Paracord Rope
    Composed of super heavy-duty nylon, the Gear Aid 550 Paracord rope is 7 individual strands woven together to create a single paracord. What makes this rope unique is that in a survival situation, it can be unraveled to supply you with things like fishing line, thread, or floss. When together, it can be used to secure tents and shelters, create a makeshift clothesline, or even be used for climbing.
  7. Polypropylene Underwear
    Getting too cold is a situation that can pose danger quickly, so finding the right warm layers to wear during a disaster is essential. Polypropylene underwear is our #1 choice for staying warm! It delivers the same warmth as thermal underwear but it will also keep you dry. Polypropylene wicks away moisture and stays warm even when wet! And, it’s cheaper than thermal, too. You can thank us later.
  8. The Ek Model 5 by KA-BAR
    This knife was one of the very first designed for both survival and combat and was originally made for marines fighting in WW2. Featuring an especially long 7 inch blade length (for a total length of nearly 12 inches), the Ek Model 5 has a durable design that allows you to be ready for anything.

The handle is made of nylon and stacked leather for exceptional gripping, and the blade is protected with an epoxy resin so it’s ready for any kind of weather.

LSC Survivalist Graphic

Be Prepared with Plastic

 
Just one day after the deadly Moore, Oklahoma, tornado in 2013, survivor Kelly Byrne reflected, “You don’t realize how quickly it happens.” If that moment comes, be prepared with plastic. Kelly had just 16 minutes. How long will you have?

History of Polypropylene – A Timeline

Lone Star Chemical History of Polypropylene - A Timeline

It was not until the last one hundred years or so that plastic became the name for a category of substances called polymers. Just for fun, let’s look at at the history of polypropylene, a plastic polymer.

So what defines a polymer? According to the Science History Institute, the word polymer means “of many parts.” Actually, polymers consist of long chains of molecules. Polymers abound in nature. Cellulose, the material that makes up the cell walls of plants, furnishes us with a good example of a very common natural polymer.  

Polypropylene is a Polymer

In the mid-1900s, scientists learned to make polymers from a process that uses carbon atoms from fossil fuels. These man-made polymers chain together atoms in repeating patterns. Accordingly, their repeating patterns extend much longer than the chains that occur in natural polymers. These long chains, and their repeating patterns in which they are arranged, make man-made polymers stronger, more lightweight, and even more pliable than their natural counterparts. One plastic polymer in particular serves as our focus today. Polypropylene. 

The Origin of the Word “Plastic”

Before we look at the history of the plastic known as polypropylene, let’s think about the origin of the word plastic itself. One might not think that a common word such as plastic would be more than 400 years old. In fact, 200 years before the first man-made plastic, parkesine, came to light in the mid-1800s, the word plastic was used to refer to something that could be easily molded, something that was pliable, or easily shaped.

Interestingly, our English word “plastic” derives from the Latin word plasticus and the Greek word plastikos, both meaning “able to be molded, pertaining to molding.” Most likely, Greeks used plastikos to describe unhardened versions of clay.” (Source: Science History Institute)

Now, back to polypropylene, and a look at its historical timeline.

The Value of Plastic Products Made from Polypropylene

A synthetic resin, polypropylene arises from the buildup (polymerization) of propylene – a gaseous hydrocarbon obtained from petroleum. Makers of plastic products mold or extrude polypropylene into many offerings. Fortunately for them, these plastic products demonstrate toughness and pliability. Their value comes from their light weight and their heat resistance. In addition, polypropylene gets woven into fibers for a variety of uses in household and industrial textiles.

The History of Polypropylene - The Timeline

 

Polypropylene and Its Use Today

Lone Star Chemical plastic manufacturingFrequently, polypropylene is melt-spun into fibers. “Polypropylene fiber is a major factor in home furnishings such as upholstery and indoor-outdoor carpets. Numerous industrial end uses exist as well, including rope and cordage, disposable nonwoven fabrics for diapers and medical applications, and nonwoven fabrics for ground stabilization and reinforcement in construction and road paving. These applications take advantage of the toughness, resilience, water resistance, and chemical inertness of the polymer. ” (Source: Britannica)

In general, the plastics we use today are well-known for their long-life, their strength, and their flexibility for design. There are myriad creative and beneficial applications in sectors ranging from medicine to consumer products. Plastics find usage in technology, aerospace, construction, and the automotive industry. Indeed, you could probably lay your hands on something made of plastic without taking more than five steps from where you are. Plastics, that substance that proved itself “able to be molded,” has molded a world of refinement, sophistication, comfort, innovation, and ever-expanding progress.

Plastics Make It Possible

Plastics Makes It Possible

Plastics improve life in innumerable ways. Our English word “plastic” comes from the Latin word plasticus and the Greek word plastikos. These mean “able to be molded or formed.” Of the countless uses for plastics, healthcare stands as especially significant. There, plastics bring greater longevity and quality of life. 

For those who have suffered limb loss, the word “plastics” means more than something that is “able to be molded and formed.” To them, plastics mean holding hands with their spouse. It means playing catch with their son in the backyard. It means still getting to race in that marathon on their bucket list. Indeed, for those who have lost a limb, plastics mean much more. For them, plastics mean life. 

Limb Loss

 

Recovery from limb loss poses a complex physical and mental journey. This process calls for human expertise and a world-class fabrication of suitable prostheses and orthotics. The versatility of plastics and polymers allows engineers, scientists, and inventors to rapidly design, test, and experiment with raw materials to develop prostheses that return mobility and motor function, improving the quality of life for amputees around the world. 

And what exactly does this have to do with plastics? Everything. None of today’s modern prosthetic advancements would be possible without the use of plastics.

Plastics for “Living Lightly”

 
It seems the heavier the world gets, the more it needs lightness. That’s why Native Shoes exists. Founded in 2009, Native Shoes fuses innovation, creativity, and curiosity to create a lighter, happier world. They innovate using bio-based materials and animal-free design. They recycle well-loved shoes via the Native Shoes Remix™ Project. All in all, they make it easy for all to Live Lightly, every step of the way. 
 

Plastics: Change is the Constant

 
To live lightly—that motto could well sum up what so many in the plastics world are striving to do. We’ve covered a lot of innovative ground in this series. Our conclusion? The world of plastics, polymers, resins, and other materials today sees its greatest epoch of change, ever. The word “plastic” itself means moldable, changeable, shapeable. Never have these materials been put through so much scrutiny, study, and scientific rigor. We find ourselves in special time to be a part of this world. And someday we may all look back on the 2020s as the most eventful years of our trade.
 
Thank you for following along in this series. There’s just a little bit left to say, further below. But meanwhile, thank you for being involved in an industry we all know and value.
 
In case you missed them, make sure to read parts 1 & 2 of this series:

  Part 1: The Plastics Transformation
  Part 2: Shifting Winds: Plastics Face Big Changes

Plastics Make It Possible

Plastics comprise the most commonly used material for “active prostheses.” Polymers have the unique ability to mimic characteristics of human body parts, such as energy return, flex, and strength. Science revolutionized prostheses via the development of plastic materials. These help make protheses lighter, stronger, more flexible, and more able to mimic the function of a natural limb. 

Today’s devices are also more functional, durable, and comfortable because they utilize plastic, aluminum, and composite materials. Such materials allow for patient-molded and individually fitted prostheses. Moreover, with the advent of microprocessors, computer chips, and robotics, prostheses transcend barriers, providing basic functionality. They help return amputees to their previous accustomed lifestyles.

A Future Shaped By Plastics

Meet Mike Moran. A painter from Michigan who’s life was drastically changed during a work site accident. What happened next was nothing short of a miracle.

Nerve pain poses a huge problem to amputees in their journey towards recovery. The nerves in an amputee’s residual limb continue to grow and send motor signals to their missing arm or leg. But with no muscle to grow into, or innervate, they gnarl into a tangled mess called a neuroma. And neuromas often cause pain, even severe pain, for the amputee. 

The Miracle of RPNI

Physicians in Michigan came up with the idea of putting small pieces of muscle on the end of the nerves. That way, the nerve would grow back into that muscle and re-innervate it. From there, surgeons could then use that muscle as an interface to control the prosthesis. They called it a “regenerative peripheral nerve interface,” or RPNI. 

Originally, their plan was to coat the small pieces of muscle with an organic electro-conductive polymer. Then they would attach them to a nerve responsible for a motor function. Now, let’s say, an amputee thinks about moving his or her thumb. The muscle at the end of the nerve that controls thumb movement would fire a signal. Polymers would pick up that signal and convert it to an electronic signal. The signal will wirelessly control a motor to move the thumb on the prosthesis.tic

“Enormous Impact” of Plastics

 Dr. Paul Cederna, professor of plastics and biomedical engineering at the University of Michigan, performed the procedure. He underscored the significance of such a medical breakthrough. 

He said, “The more [your prosthetic limb] moves realistically and the more sensation it provides, the more it will be incorporated into your body image. The more it’s incorporated into your body image, the more likelihood you start using it like a natural limb. To make gestures or to hold your child’s hand. To play the piano or type at a keyboard… I see the patients, and I know what they’re going through. And I know what we’re doing has an enormous impact.”

 

The Future Beckons

The impact plastic has on our lives? Astronomical. Can you think of any one material that does more? Life, today, doesn’t happen without plastic materials. Life, tomorrow, won’t happen without plastic materials either. Over the last 155 years, plastics evolved from being a replacement for ivory to filling myriad uses. They help power our homes. They keep our food safer for longer. Plastics make our cars more fuel efficient. Used in artificial limbs, they allow people to sense touch just as human skin does. No other material in the history of humanity has ever had the versatility, or the impact, of plastics. Just ask Mike.

Polymers and Other Plastics: Times of Transition

Polymers and Other Plastics: Times of Transition

With this concluding segment of our series, we turn our attentions to polymers in particular.

The 2020s have wrought changes in all segments of society, industry, and daily life. The field of plastics and polymers appears as affected as any. In this Part 3 of “Plastics: What Lies Ahead?” we share a roundup of eye-opening directions, departures, and developments in the world of plastics, polymers, resins, and their like.

 

As we have noted in the two previous articles, politics have been paramount in the changes we are seeing. The push for biodegradable plastics, recyclable plastics, and re-usable plastics (as opposed to single-use plastics) has altered the landscape. 

Polymers and Today’s Shifting Winds

And the news that emerges from that pre-ponderance of the market is generally slight, if only because petroleum-based plastics are slogging through their worst days ever, in terms of public opinion. It’s worth saying, though, that even the petrochemical industry is hard at work with developments and innovations to minimize or even, in some cases, eliminate their perceived negatives. 
 
But bio-based alternatives are all the rage today, and that’s what has dominated our series. Further, that’s what dominates our coverage in this article as well. We only share the “other side” here to keep things in perspective. It’s not just conventional plastics that have suffered in image—it is all oil and gas commodities altogether: fuel, fertilizers, and a whole range of applications. 
 

Polymers Can Be Biodegradable

 
But public opinion favors renewable, recyclable, biodegradable, and sustainable alternatives, and the 2020s have exploded with them.
 
Corporations seem bent on outstripping one another in new product entries and endeavors. Even such a company as Republic Services is getting into the act. Republic Services, Inc., specializes in waste removal specialist. Not exactly a business one connects with environmentalism.
 

Know Your Plastics

Republic created this Know Your Plastics infographic.
To commemorate Earth Day in 2022, Republic Services has shared myth-busting plastics/polymer recycling tips to help consumers be better recyclers. The accompany chart (Know Your Plastics!) was created to help consumers in recycling efforts.

As Republic observes, demand keeps growing for recycled plastic to use in consumer packaging. So consumers need to ensure that plastic bottles, jugs, and containers make their way into the recycling bin.
 
Today in the United States, only about 30 percent of single-use plastic bottles and jugs are recycled. While recycling rates are low, demand is high for this recycled plastic. Many consumer brands have pledged to use more recycled content in their packaging. Some states are even requiring it.
 

Myth Busters

 
Republic shared its top 5 plastics recycling myths, which we repeat here:
 
Myth: Plastic doesn’t really get recycled. Fact: Plastic bottles, jugs, containers and tubs are widely accepted for recycling in communities across the country, and there is strong demand for these materials.
 
Myth: Anything plastic can go in your recycling bin. Fact: Know what to throw. Generally, plastic bottles with necks or handles, or plastic containers and tubs are recyclable in your curbside container.
 
Myth: Plastic grocery bags can be recycled curbside. Fact: Plastic bags require special handling to be recycled and should not go in your curbside container. Return them to collection bins at the grocery or big-box store.
 
Myth: You should bag your recyclables. Fact: Recyclables should never be bagged. Place them loose in your recycling bin. Plastic bags can wrap around and jam equipment at recycling facilities, causing delays or damage.
 
Myth: Anything with a recycling symbol should go in your recycling bin. Fact: The “chasing arrows” symbol generally identifies the type of plastic used in a container. Or it indicates that an item contains recycled content. But it does not mean that an item is recyclable.
 

It’s Called a Polymer Center

Republic Services advances plastics recycling and circularity through development of the nation’s first integrated plastics recycling facility. Republic’s first Polymer Center intends to process plastics from recycling facilities across the West. They will also produce high-quality recycled plastic for use in consumer packaging. The center will open in 2023 in Las Vegas, with plans for two to three additional sites for national coverage to follow. For more information, visit RepublicServices.com/PolymerCenter.
 
For more recycling tips, visit RecyclingSimplified.com.
 

Polymers and Other Plastics Improve Electric Vehicles

Electric vehicles (EVs) keep gaining market share, and plastics supply much of the reason why.
 
Rapid adoption of electric vehicles across the globe accounts for one of the change. So does increasing use of polymers in interiors of EVs. And increasing focus on manufacturing lightweight electric vehicles also will drive market growth.
 
According to the latest report by Reports and Data, the global electric vehicle (car) polymers market size was $6.9 billion in 2020 and should reach $418 billion in 2028. That would mean that the niche registers a Cumulative Annual Growth Rate (CAGR) of 67 percent during the forecast period, 2021-2028. 
 

Polymers Save Dollars

 
The technology of electric vehicles depends on high efficiency and good strength-to-weight ratio, a trends that favors increased use of lightweight materials. Polymers provide long-term performance and efficiency gains and have proven to improve fuel efficiency by 5 percent. Rapid advancement in polymer science have further broadened their application scope in automotive applications. 
 
Polymers find wide use in sensor shields, brackets, insulation, EV charging stations, as well as in battery separators and coatings. Increasing use of polymers means reduce noise, vibration, and harshness level. They boost efficiency and performance of electric vehicles. They supply key benefits that will drive market revenue growth over the forecast period. 
 

Plastics Recycling Has High Upside

Plastics recycling, as an industry, holds potential of some $50 billion in revenues. If, indeed, the business sector embraces the niche in coming years. According to analysis by Markets & Markets, chemical companies will adopt initiatives across the value chain to improve quality of recycled plastics. And they will address sorting challenges. Governments are fast leaning towards environmental sustainability. 
 
Different economies have different recycling rates. Currently the rates range between 20-30 percent globally, although higher in developed economies. Markets & Markets’ research and analysis focused on high growth and niche markets. These should supply some 80 percent of the revenues of companies in the plastic recycling ecosystem over the next 5-10 years.
 

A Polymers Breakthrough

An organization known as Green Science Alliance has worked hard to replace petrochemical derived products with nature biomass derived chemical products. Most recently, Dr. Ryohei Mori of Green Science developed a biodegradable coating material based on PLA (Poly Lactic Acid). The process yields a product with 100 percent natural biomass.
 
A polymer first: a bio-degradable coating material made from PLA.
Classified as a thermoplastic resin, PLA, a polymer, finds use in the production of biodegradable plastic.
 
The special grade of PLA used in this coating material (see photo) is environmentally friendly and nature derived. Other additives in this product come from nature derived materials. Also producers can coat or paint this PLA. Green Science Alliance plans to apply color to make PLA based ink and paint. 
 

Polymers: PLA Usage to Nearly Double in Five Years

Indeed, PLA will go places. According to a new market research report by Markets & Markets, the trade in PLA is projected to grow markedly. From a volume of $1 billion (as of 2021), the niche should climb to $1.9 billion by the year 2026. 
 
PLA, a linear, aliphatic polyester synthesized from lactic acid monomers, biodegrades. PLA has characteristics similar to polypropylene (PP), polyethylene (PE), or polystyrene (PS). This compostable material comprises the most-used type of biodegradable plastic derived from renewable resources. That includes corn starch, tapioca roots, chips, starch, or sugarcane. 
 
Packaging comprises the largest end-use industry for PLA, with a high CAGR of 13 percent during the forecast period. The need for sustainable solutions spans several industry verticals, including food and beverages and e-commerce.
 

Getting in Step with “the Robbie”

Another polymer grabs another headline.
 
In March, the company known as Braskem announced its involvement in a new shoe line. This line employs a polyolefin produced by this company that leads the industry in that sector (polyolefin, not shoes). Teaming with the Native Shoes company, the group launched the all-new Robbie footwear. The Robbie features Braskem’s renewable and carbon negative “I’m Green (TM)” bio-based EVA polymer.
The Robbie shoe line by Native Shoes includes components made from sugar cane.
Braskem’s Renato Yoshino remarked that “Native Shoes is helping lead the movement to meet the growing consumer demand for more environmentally conscious footwear and taking fashion to the next level of sustainability. Braskem delights to work with like-minded partners around new sustainably focused products.” Braskem’s “I’m green” bio-based EVA comes from sugarcane. For more information on The Robbie visit Native Shoe online at www.nativeshoes.com/robbie-collection.
 
It seems the heavier the world gets, the more it needs lightness. That’s why Native Shoes exists. Founded in 2009, Native Shoes fuses innovation, creativity, and curiosity to create a lighter, happier world. They innovate bio-based materials and animal-free design. They also recycle well-loved shoes via the Native Shoes Remix™ Project. Native Shoes’ purpose? To make it easy for all to Live Lightly, every step of the way. 
 

Plastics: Change is the Constant

To live lightly—that motto could well sum up what so many in the plastics world are striving to do. We covered a lot of innovative ground in this series. Our summation: the world of plastics, polymers, resins, and other materials now know the greatest epoch of change this industry has ever seen.

The word “plastic” itself means moldable, changeable, shapeable. Never have these materials been put through so much scrutiny, study, and scientific rigor. It’s a special time in this world, and someday we may all look back on the 2020s as the most eventful years of our trade. 
 
Thank you for following along in this series. And thank you for being involved an industry we all know and value.
 
In case you missed them, make sure to read parts 1 & 2 of this series:
  Part 1: The Plastics Transformation
  Part 2: Shifting Winds: Plastics Face Big Changes

Shifting Winds: Plastics Face Big Changes

Shifting Winds: Plastics Face Big Changes
plastic pellets what lies ahead 2

Politics and public opinion go a long way toward steering any industry, and the plastics industry is no different. In the 2020s, the public’s rising awareness of single-use plastics and their implications has brought dramatic changes. As we continue our series on “Plastics: What Lies Ahead?” we examine the changes wrought by the market’s increasing aversion to single-use plastic products.

Clearly, the marketplace is rife with new offerings that stress bio-sourced plastics materials. But it is worth saying that some of this change is powered as much by public relations as by profit-mindedness. Yes, bio-plastics are big right now—bigger than ever. But their share of the plastics market still remains relatively small. Meanwhile, conventional plastics remain a booming industry and one that is not going away anytime soon.

Demand for petrochemical projects, particularly those focusing on plastics, is expected to increase substantially in the coming years, according to a recent article published on the news website OilPrice.com.

In a Feb. 3 article on OilPrice.com entitled “Plastics Will Fuel Oil demand for Years to Come,” reporter Felicity Bradstock observed that, for all of the rush toward bio-plastics, there is still a huge and entrenched industry that is the petrochemical industrial world. And that world, seeing as it does that governments and some political interests are pushing for greater use of electric vehicles, realizes that its gasoline refinery prospects may indeed feel the pinch.

This being so, Big Oil looks to petrochemicals as a safe harbor in this storm. States Bradstock: “The International Energy Agency (IEA) predicts that plastics derived from fossil fuels will drive almost half of oil demand by 2050, as one of the last remaining sectors to decarbonize. Judith Enck, Founder and President of the nonprofit organization Beyond Plastics, believes “Plastics is the Plan B for the fossil fuel industry.”

Meanwhile, recycling of plastic, reduction of plastic waste, and use and development of biodegradable plastic are active interests today.

A Plastics Innovation

“Thermoplastic resin” is the precise technical term for plastic, which is defined as a synthetic material that can be molded into any shape for actual use by high-temperature molding using a molding machine. To perform molding, the plastic needs to be in the form of a “resin pellet” with a size of 1-3 mm.

The production and use of biodegradable plastic is slowly increasing, although greater than 98 percent of plastics worldwide are still petroleum-based non-biodegradable plastics. In addition, the production of these petroleum-based non-biodegradable plastics are still increasing.

Biodegradable plastics can be composed of biomass such as corn, sugarcane, potato, and grains. However, as these commodities are also in demand for human consumption, alternatives, if they can be found, can pose a welcome remedy. Celluose, a non-edible biomass, can be a good alternative, although the preparation of cellulose-based resins with good properties requires the use of petroleum-based additives.

With this view, Dr. Ryohei Mori at Green Science Alliance has created a 100 percent natural biomass-based biodegradable thermoplastic material from wood, stone, and a natural deep eutectic solvent. Besides wood, stone, and the natural deep eutectic solvent, the as-prepared material was also composed of environment-friendly natural materials; hence, this material was composed of 100 percent natural materials—i.e., no petroleum. In addition, not only wood and stone but also all of the other composed materials were cost-effective.

100 % Natural Biomass Biodegradable Plastic Resin made from Wood and Stone and Natural Deep Eutectic Solvent

Analysis and further improvement of the resin properties of this novel and innovative material, as well as sample work for actual industrial use, are currently underway in Green Science Alliance.

Plastics are the Target

Target Corporation on March 9 announced Target Zero, a new initiative that responds to growing customer interest in products that help reduce waste. Customers will now see a Target Zero icon in stores and online that will signal products and packaging across Target’s assortment designed to be refillable, reusable, or compostable, made from recycled content, or made from materials that reduce the use of plastic. Hundreds of new and existing products from customer-favorite brands across Target’s Beauty, Personal Care, and Household Essentials categories will be among the first in the Target Zero collection, with plans to expand the assortment in the future.

“Target Zero unlocks important progress toward our Target Forward ambitions, each of which require collaboration from our partners and action from our guests to be realized,” said Amanda Nusz, senior vice president of corporate responsibility and president of the Target Foundation, Target. “By making it easier for our guests to identify which products are designed to reduce waste, Target Zero helps them make informed decisions about what they purchase and advances a collective impact across our brand partners, our product shelves, and within our homes and communities.”

Target ZeroThe Target Zero icon will be seen by guests on shelves in-store, and through a dedicated online experience at target.com. Hundreds of products from brands, including Burt’s Bees, PLUS, Pacifica, and more, are among the first to be featured. Additionally, select products from Grove Co. and Target’s owned brand Everspring were to join the collection beginning in April.

Plastics Frontiers: Bio-Naphtha is Now a Thing, Too

Honeywell announced earlier this year that it has introduced a new solution for producing renewable naphtha for petrochemical production using the commercially proven Honeywell UOP Ecofining technology. The new pathway can produce high yield of naphtha from sustainable feedstocks like used cooking oil and animal fats.

Prior to the introduction of renewable naphtha solution, the UOP Ecofining technology has been used to produce predominantly Honeywell Green Diesel and Honeywell Green Jet fuel, with small amounts of bio-naphtha being produced as a secondary product. The same Ecofining technology can be adapted to produce high yields of renewable naphtha as its predominant product, reflecting the versatility of the Ecofining design and ability to produce a range of products based on market needs.

“We are actively engaged with customers to drive new technology adoption, as renewable petrochemical feedstocks have grown in interest as consumers prefer more bio-based products,” said Ben Owens, vice president and general manager, Honeywell Sustainable Technology Solutions. “We see renewable naphtha produced from the UOP Ecofining process as a proven solution available today to help petrochemical producers reduce the carbon footprint of their products compared to using petroleum-based feeds.”
 

Enter the “Piranha”

Packaging continues to be a specialty where bio-sourced plastics are making big strides.
 
European thermoforming packaging specialist Waddington Europe, a division of Novolex, has introduced an innovative recyclable tray for meat, fish, and poultry products. The container, called Piranha, is sealed using a series of raised teeth that run around the sealing flange, instead of relying on a layer of polyethylene or adhesive, which in other applications is used to seal the lid of “modified atmosphere packaging” (MAP). The raised teeth maintain the seal’s integrity even if the flange becomes contaminated by animal fat, which can interfere with closure on traditional packaging for meat, fish, and poultry products.
Piranha Packaging
An innovative recyclable tray for meat, fish, and poultry products, dubbed Piranha, employs raised teeth that run around the sealing flange, ensuring the seal's integrity.

With Piranha, greasy contaminants are forced into the channels between the raised teeth, leaving the peaks clear and clean to contact the PET top web. As a mono-material package, the tray is capable of being fully recycled. To learn more about Waddington Europe and its packaging solutions, visit www.waddingtoneurope.com.

Polyethylene Sees Growth Ahead

The global market for polyethylene is estimated to be worth $123 billion currently and is forecast to reach the $142 billion mark by by 2028, charting a Cumulative Annual Growth Rate (CAGR) of 2.5 percent along the way. Polyethylene’s increasing use in various end-user applications such as packaging, consumer goods, and construction materials is expected to fuel the market’s growth.

Furthermore, features of polyethylene, such as its qualities of being highly adaptable, extremely lightweight, and economical, as well as its excellent rigidity, superior flexibility, and easily recyclabilityare expected to propel PE adoption. In addition, as researchers are finding, the introduction and development of bio-based and biodegradable polyethylene will almost certainly create new growth opportunities for the polyethylene market.

Looking Ahead

And, again, let’s not forget that conventional, oil-and-gas based plastics are still in the picture, and in a big way.

As Bradstock (cited earlier) writes, “Plastics are commonplace in the developed world, with governments now planning to curb the use of certain products such as single-use plastics. But as energy firms invest in expanding their petrochemicals business, many are aiming their products at the Asian and African markets, where they expect demand to continue increasing. Most of these plastics are currently being produced in the United States and the Middle East, with China being the biggest importer.”

 

Read part 3 of this series:  Polymers and Other Plastics: Times of Transition

The Plastics Transformation

The Plastics Transformation
plastic pellets what lies ahead 1
Plastics improve quality of life. Those of us in the plastics industry see this every day. Just the same, from time to time, it helps, in any line of work, to pause and test the prevailing winds. Plastics are our world. And no substitute exists for having a sense of what one’s world holds. In a fast-changing realm like the plastics industry, staying abreast of change means everything.
 

We want to help our customers and others interested in this viable, versatile niche of plastics, polymers, resins, and the like. Accordingly, we have researched many weeks’ worth of trends, announcements, and notices from important players in our field. 

 
We serve up some highlights in a three-part series intended to cover the latest developments in our world. And not just recent developments, but projections for the next 5, 10, and even 15 years.
 

Plastics and the Circular Economy

 
The good news? Growth prospects loom. When the topic turns to bioplastics and other new-wave offerings, growth appears exponential already. But even in the field of conventional petrochemical plastics, growth cannot be denied.
 
The buzzword today? “Circular Economy.” We encountered that term frequently when we conducted our search. It seems that the corporate world keeps putting its weight behind this goal. Recyclable, or sustainable, offerings dominate the news in plastics coverage.

Petro Products: Touted Less

 
Meanwhile, when it comes to products announcements or market assessments of the traditional (petrochemical) plastics world, companies show reticence. But that doesn’t necessarily mean they aren’t aggressively active on that front. It may instead mean that petrochemical-based plastics do not enjoy the same vogue as their bio-based competitors. Therefore companies simply do not wish to tout them—not in 2022, anyway.
Honeywell-New-Tech-Plastics
Avangard NaturaPCR complex in Waller, Texas
A Feb. 3 article on OilPrice.com by reporter Felicity Bradstock holds that “Plastics Will Fuel Oil Demand for Years to Come.” Bradstock observed that as the demand for petrochemicals increases worldwide, energy firms have a fallback. 

If oil demand in some sectors wanes there still exists a use for their ‘black gold.’” That use? Plastics.

Petrochemicals Hold Promise 

 

“When we think about oil, we often think about it as an energy source, giving little consideration to the other ways in which it’s used,” Bradstock wrote. “But much of the oil from around the world actually goes into producing everyday products. These products include clothing, tires, digital devices, packaging, detergents, and fertilizers. 

 

In 2018, petrochemical feedstock accounted for around 12 percent of global oil demand. This figure will increase substantially over the next few decades. Experts expect 10 million metric tons of growth in the petrochemicals industry every year between now and 2050.” 

 
A March 3 report from Valuates Reports finds that the market for extruded plastics will see growth. They predict a Cumulative Annual Growth Rate (CAGR) of 4.6 percent between now and the year 2030. This niche currently carries a value of $186 billion, but by 2030 will weigh in at $289 billion. 
 
As the article stated, “The extruded plastics market is segmented by material type (polyethylene, polypropylene, polyvinyl chloride, polystyrene, and other polymers). As well as by application (pipes and tubing, wire insulation, window and door profiles, films, and other types). And by end use (building and construction, packaging, automotive, industrial, and other types).” Researchers assessed all these submarkets. 
 
Increased packaging industry application and demand, as well as construction activities, will drive the extruded plastics market growth.
 

Plastics Injection Molding to Follow Suit

 

The global injection molding market size will reach $398 billion by 2030, according to a March 30 report by Grand View Research, Inc. They expect the market to expand at a CAGR of 4.8 percent (slightly higher than the growth quotient for extruded plastics) from 2022 to 2030. 

The market remains driven by the rising demand for injection-molded components from various end-user industries. These offer cost-effective and efficient methods for manufacturing high-volume production of parts and products.
 
This market witnessed growth especially from the medical industry, with the emergence of the COVID-19 pandemic, as plastics offer offer accuracy, a high range of operation, repeatability, and cleanliness. Furthermore, packaging manufacturers leverage injection molding with robotics to run faster production rates with cost-effectiveness.
 

The market has witnessed a surge in adoption in recent years. The manufacturing technology employed for producing complex products made the difference. Players incorporate industry 4.0 in their process, thereby optimizing the requirement of raw materials, lowering costs, and increasing automation and flexibility.

The COVID-19 pandemic caused supply chain disruptions in 2020-21. That meant losses for the service providers as demand from various end-user industries was halted. 

Resins to the Rescue

 

The demand for plastic injection molding is witnessing significant growth due to high tensile strength and high-temperature endurance. These factors led to the increased usage of engineering-grade plastic resins for molded products. Moreover, plastic resins enable a reduction in manufacturing waste, product weight, and overall manufacturing costs. 

Companies providing molding services acquire the latest technologies to meet the changing demands from the medical industries and increase manufacturing capacity. 

 

Plastics Recycling Will Only Get Bigger

 

According to a recent market research report published by P&S Intelligence, the recycled plastic market value will increase. Observers say it will grow to $124 billion by 2030 from an estimated $59 billion in 2021. That rate amounts to a CAGR of 8.5 percent. In recent years, a number of companies started to collect plastic waste and recycle it into reusable resins and fibers. 

These companies include MBA Polymers Inc., Vikoz Enterprises Inc., Phoenix Technologies International LLC, and Terracycle U.S. Inc. Also DS Smith Plc, KW Plastics, PETCO, Custom Polymers Inc., and Waste Connections, Inc.
 
As P&S observes, “In the coming years, the value of recycled packaging plastic sales will grow at a healthy rate [because single use design dominates the market for packaging at present]. 

With the rising demand for packaged consumer goods, the plastic packaging sector keeps growing, as does the amount of waste plastic. Additionally, governments in several countries implemented rules that seek to curb the volume of plastic waste –  waste that can’t be recycled.”
 

In the coming years, Europe will see the highest market CAGR, as that continent fulfills on to reduce its plastic waste. As per Plastics Europe, 35 percent of the plastic waste collected in Europe went to recycling centers. 

Moreover, China, once the major importer of such waste, banned the inflow of certain kinds of plastic waste in 2017. That came under its National Sword Policy, which made it imperative for the waste to be reprocessed at the source itself.

 

Plastics Recycling Technology Takes Another Step

 
Honeywell announced earlier this year its intent to form a joint venture with Avangard Innovative to build an advanced recycling plant in Texas. The facility will use Honeywell’s recently announced UpCycle Process Technology to transform end-of-life plastic waste into recycled polymer feedstock. Such feedstock goes toward creating new plastics.
 
Honeywell’s new UpCycle Process Technology reduces the need for fossil feeds in the creation of virgin plastics. Honeywell seeks to enable a circular economy for plastics.
 

Avangard Innovative, the largest plastics recycler in the Americas, becomes the first to deploy the UpCycle Process Technology in the United States. Honeywell and Avangard intend to form a joint venture to co-own and operate a facility within Avangard’s NaturaPCR complex in Waller, Texas. 

The planned advanced recycling plant will transform 30,000 metric tons of mixed waste plastics into Honeywell Recycled Polymer Feedstock per year. Production begins in 2023. 
 

Making the Plastics Switch

 

Early in 2021, a Dallas-based start-up company raised some $3.25 million to revolutionize the food-packaging industry. They aim to develop high-quality, biodegradable plastic alternatives. The funds should help them expand their product offerings and develop their supply chain infrastructure. 

PlantSwitch was founded two years ago by Dillon Baxter and Maxime Blandin, both graduates of Southern Methodist University (SMU), founded PlantSwitch two years ago. Alums of the SMU men’s golf team, they strive to offer\single-use biodegradable solutions. PlantSwitch will produce products that function like traditional plastic, and at an affordable price.
PlantSwitch Co-Founders Maxime Blandin and Dillon Baxter
PlantSwitch first launched as a supplier of biodegradable straws and cutlery. Now they plan to introduce numerous other renewable packaging products. These include cups, plates, water bottles, food takeout containers, and cosmetic and CPG packaging products.
 
The company also has the capacity to create custom products for large-scale clients. Notable customers include Hillstone Restaurant Group, Pressed, Discovery Land Company, Catch Hospitality Group, Just Salad and The Hampton Social, among others.

 

Green Packaging Market to Grow as Well

 
A recent report published by Allied Market Research asserts that green packaging will grow significantly. Globally, the CAGR should track at 6.6 percent between 2022 and 2031. As recently as 2020, this market commanded some $164 billion in business. By 2031, the market will reach $338 billion.
 
The global green packaging market stands to rise due to two factors. One, rising awareness among consumers about green packaging techniques. And two, a surge in environmental concerns leading to sustainable packaging developments.  
 

Based on application, the food and beverages segment held the highest market share in 2020. As such, it accounted for around three-fifths of the global green packaging market. Food and beverages will maintain leadership status throughout the forecast period. Observers credit growth in consumer awareness about health and the emergence of substitutes. 

However, the healthcare segment stands to chart the highest CAGR – 7.4 percent – from 2021 to 2030. Medicines can include complex chemical solutions. These can react with the harmful chemicals in some packaging material. Accordingly, the reaction can destroy the medicine composition. Thus, healthcare’s green packaging niche has its work, and its market, cut out for it.
 

Even Watches Are Getting in on the Act

Casio has introduced its Pro Trek timepiece, which features biomass plastics.
On April 5, Casio America, Inc., announced the latest addition to its Pro Trek line of outdoor watches. The new PRW61 is the first Casio watch to be made with biomass plastics sourced from renewable organic substances. 

 

Produced from regenerable resources, biomass plastics have much to commend them. They merit attention as a material that can reduce environmental impact by curbing carbon dioxide emissions.

 
As part of its focus on sustainable development goals, Casio pursues several environmentally friendly initiatives. One of these is a shift from plastic to recycled paper in packaging for the PRW61. Moving forward, Casio contributes to efforts to build a circular economy by expanding its use of sustainable materials in the design of other watch models.
 

According to a 2021 report by Markets & Markets, the market for biodegradable plastics will grow at a CAGR of 25 percent by 2026. Last year the niche stood at $7.7 billion.

 
The term “biodegradable plastics” means plastics that undergo biodegradation. (Biodegradation involves the action of naturally occurring micro-organisms such as bacteria, fungi, and algae). The biodegradable plastics market includes both bio-based biodegradable plastics and synthetic/petrochemical-based biodegradable plastics. 
 
The market enjoys growth across the world due to awareness and to stringent government regulations about non-biodegradable plastics. Producers choose biodegradable plastics for packaging, consumer goods, and textiles. They use them also for agriculture and horticulture, among other end-use industries.
 

PLA Matters

 
PLA accounts for the major share of the market in terms of value.
 

PLA Matters

 
PLA stands as the largest segment of the biodegradable plastics market. PLA finds use in various end-use industries such as packaging and bags and consumer goods. Made from renewable resources, PLA boasts features of being compostable as well as biodegradable. PLA comes from corn starch (in the United States and Canada), tapioca roots, chips, or starch (mostly in Asia), or sugarcane. 
 
This makes PLA non-toxic and an environmentally friendly material. The key applications of PLA include thermoformed products, namely drink cups, takeaway food trays, containers, and planter boxes. It has good rigidity and allows for replacement of polystyrene and PET in such applications. 
 
The rapid adoption of PLA arises from its economical advantages, compared to other biodegradable plastics.
 
Finally, to come full circle, we share another thought expressed on OilPrice.com, where writer Felicity Bradstock conveyed this caveat. “Researchers work hard to develop more sustainable petrochemical alternatives, such as bio-based plastics and specialty chemicals. [But] these products remain much more expensive than fossil fuel-derived products. 
 
Despite a huge recent drive to develop renewable energy alternatives, petrochemical-alternative production remains in its infancy. Oil and gas firms stand to benefit.”
 
 

Read part 2 of this series:  Shifting Winds: Plastics Face Big Changes